Engine: Other Porsche Boxster 986 рестайлинг

ADJUSTING TOOL

Note. If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.

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1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. (Scheme 285) The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated position Boxster. The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Fasten the support for the manual transmission with 1 M8 x 25 bolt.
6. Fit complete retainer plate on the workshop jack.

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Note. The engine is removed downwards complete with the manual transmission.

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1. Position the vehicle at the specified points on a lifting platform.
2. Open both the luggage compartment lids.
3. Cover the vehicle. Cover the vehicle with protective covers in such a way that the body can not be damaged.
4. Move convertible top or convertible-top compartment lid to service position. Open the convertible top until the convertible-top compartment lid is half open.
5. Detaching cloth covering. Disengage the rear strip on the left and right sides of the cloth covering in downward direction.
6. Detach tension cables. Press the ball socket of the tension cable out of the ball head of the adjusting piece on the left and right.
7. Move convertible top to service position. To do so, press the tension bow of the convertible top towards the main bow, until it reaches its locking point.
8. Move the convertible-top compartment lid to service position and secure. Disengage the convertible-top compartment links at the extreme bottom. To do so, disengage the clips at the left and right and pull the links off the bolt.
9. Press the convertible-top compartment links forwards until the two bores coincide and a 5 mm mandrel can be pushed through them.
10. Remove left-hand seat. For better accessibility, remove the left-hand seat of the car. Unscrew the four internal-serration screws, disconnect all the electrical plug connections and remove the seat.
11. Open the rear wall cover. To do so, remove the oddments tray behind the seats and remove the rear wall lining. Then undo the 6 fastening screws and the 2 fastening nuts -arrows-. (Scheme 292) CAUTION: Danger of short circuit! First remove the ground terminal. Cover the terminals. Never connect (short circuit) the terminals.
12. Disconnect battery. Before disconnecting, find out the relevant theft codes (e.g. radio) if necessary. At the battery, disconnect the ground terminal and remove the ground cable. Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199496-S08906116372005101900000). Remove the rear spoiler. «REMOVING AND INSTALLING REAR SPOILER»(ref-199811-S17067956542005102000000).
13. Remove rear bumper. While doing so, pay attention to the connection for the number plate lighting. Refer to «REMOVING AND INSTALLING REAR SPOILER»(ref-199811-S17067956542005102000000).
14. Remove left and right wheel housing trims.
15. Remove the rear part of the underbody cover.
16. Lift the vehicle. Before lifting, check that all fastening points of the diagonal braces are easily accessible. Pay particular attention to the threaded part -C-. (Scheme 297)
17. Undo the fastening screw -C- and the collar nuts -D.- and remove the diagonal braces -B- together with the holder -E-. (Scheme 298)
18. Remove stabilizer.
19. To do so, unscrew the two fastening screws at each of the two bearing surfaces on the left and right.
20. Unscrew the stabilizer on the left and right of the links.
21. Detach rear cross member (aluminum V-member) on the body.
22. Undo the cable. Undo the engine cable on the rear-axle support. The cable must be countered with a suitable wrench and must not be twisted.
23. Undo halfshafts. To do so, undo the fastening screws of the halfshafts on the transmission. Fit protection on to the halfshafts.
24. Unclip and detach the oxygen sensor plug connection from the holders of the rear-axle support. On an OBD II vehicle, additionally disconnect the oxygen sensor plug connection in the rear wing area. Press the heat shield aside and disconnect the plugs.
25. Remove rear mufflers. To do so, secure the rear mufflers with a transmission jack. Then undo the flange connection between the catalytic converters and the exhaust manifold. Undo the three hexagon-head bolts on the exhaust bracket. NOTE: When lowering, do not damage the oxygen sensors, cables and plugs. Attach protective sleeves around the oxygen sensor plugs.
26. Remove the front lining in the rear luggage compartment. Lever off plastic clips using a commercially available removal tool.
27. Remove the rear-axle support. Unscrew the four fastening screws and remove the rear-axle support to one side.
28. Drain coolant. To do so, remove the screw plug of the coolant circuit on the coolant guide housing. Collect coolant in a clean container.
29. Disconnect coolant hoses. Open the supply and return lines for coolant on the engine and pull them off. Then close all openings. Collect emerging coolant in a clean container. CAUTION: Danger of fire! Collect emerging fuel. Avoid ignition sources and naked flames.
30. Detach the fuel return line. Disconnect the fuel return line under the vehicle floor by pressing gently on the button and pull apart. Collect emerging fuel. Close off the open ends of the line immediately. Then open the holder on the body and remove the line.
31. Disconnect the steering lines. Remove the small undersealing on the left vehicle underside (six plastic nuts). Disconnect the two hydraulic lines of the power steering on the vehicle floor. To do so, undo the threaded part and disconnect. Any emerging Pentosin must be collected.
32. Disengage the retaining clips for the power-assisted steering lines and the brake vacuum hose and remove the lines.
33. Unscrew the heat shield on the transmission. To do so, unscrew the two fastening nuts and remove the plate.
34. Disengage shift cables on the transmission. Disengage the cables with the commercially available tool.
35. Detach the shift cables. Unclip the shift cables on the transmission mount. Then pull the shift cables upwards out of the engine compartment and set them aside. WARNING: Risk of damage! When the slave cylinder is removed, do not actuate the clutch again.
36. Uncouple clutch slave cylinder. To do so, unscrew the fastening screw and remove the clutch slave cylinder. Tie the cylinder with a wire.
37. Disengage the accelerator cable. Remove the cover on the deflector box and disengage the accelerator cable.
38. Disconnect the electric plug on the hot film mass air flow sensor. Then disconnect the connecting hose between the hot film mass air flow sensor and the throttle body. To do so, disconnect the hose clamp on the hot film mass air flow sensor.
39. Press the spring band clamp on the oil filler hose apart and push it aside. Pull off the oil filler hose; heat, if necessary.
40. Disconnect the fuel supply hose. Make sure without fail to counter with a suitable wrench when doing this. Collect emerging residual fuel. Then disconnect the ground cable.
41. Disconnect vacuum line for the brake booster. To do so, remove the grey snap ring. Then push the inner sleeve -1- against the outer sleeve -2- and pull off both sleeves together in the direction of the arrow. (Scheme 319)
42. Disconnect B+ separator box. To do so, undo the hexagon nut in the separator box. Remove the cable and lay to one side.
43. Remove the supply tank of the power steering system. To do so, suck fluid out as much as possible. Then open the bayonet lock on the bottom of the expansion tank and remove the tank. Close the opening in the servo pump with a clean plug. NOTE: In vehicles with air conditioning, the points 45 to 48 must also be carried out. Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
44. Remove drive belt. Mark the running direction of the drive belt with a colored pen. Slacken belt by turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.
45. Undo the rear fastening screw of the air-conditioning compressor from above. The screw is positioned between the intake manifolds of the fifth and sixth cylinders.
46. Loosen air-conditioning compressor. To do so, undo the two front fastening screws -(arrows)-. (Scheme 324) Disconnect the electrical plug. NOTE: The air-conditioning compressor can be removed from the vehicle more easily if the engine has already been lowered.
47. Set the air-conditioning compressor with the hoses connected to one side or lift it out of the engine compartment and set it on a suitable base.
48. Remove the rear luggage compartment lining. To do so, lever out the rear fastening clips and remove the lining from the luggage compartment.
49. Disconnect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, raise the lock at the side and pull the plug out.
50. Lock the ground point of the engine control module.
51. Unplug the engine control module. Open the topmost plug by actuating the side button and pull out. Remove the other plugs from the top down. To do so, press the locking button in and push the locking bar upwards.
52. Uncover the engine wiring harness. To do so, press the rubber sleeve on the luggage compartment rear wall inwards and guide the wiring harness towards the engine compartment, if the engine is to be lowered later.
53. Disconnect the plug connection at the guide tube of the oil dipstick. To do so, press the two tabs together and unclip the tube. NOTE: It is recommended to position the complete retainer plate using a transmission jack first. Only then should the workshop car jack be placed underneath.
54. Place pre-assembled engine retainer plate with transmission support on the crankcase or transmission. CAUTION: Risk of damage! When undoing the multi-tooth nut, the mount is destroyed!
55. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
56. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
57. Lower the engine-transmission unit carefully. Ensure that there is sufficient clearance for the components. The engine wiring harness must be guided during the lowering procedure. WARNING: Risk of damage! Only place the vehicle on its wheels or push it after the rear-axle support, the sheetmetal brace and both the diagonal braces have been installed.

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SPECIAL TOOLS

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SPECIAL TOOL AND EXPLANATION

Note. If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.

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1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. (Scheme 341) The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated positions Boxster. The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Fasten the support for the manual transmission with 1 M8 x 25 bolt.
6. Fasten complete retainer plate on the workshop jack.

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1. Check the fuel hose for correct routing. The fuel hose is routed behind the engine wiring harness.
2. When installing the rear-axle parts, it is essential to observe the correct sequence. The sheetmetal brace should be installed first, then the diagonal brace and finally the rear-axle support.
3. The V-brace must be fitted before the exhaust system is installed.
4. Finally, perform a suspension alignment.
5. Read out fault memory.

Note. In order to facilitate the fitting of the air-conditioning compressor, it should be moved back into its installation position during the running-in of the engine.

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1. Lift the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time. When lifting, pay particular attention to the clearance between the rear-axle longitudinal support and the VarioCam cable. Place the air-conditioning compressor in its installation position at this stage.
2. Push the engine wiring harness through the bulkhead and into the luggage compartment before the final installation position is reached.
3. Tighten engine mount. Tighten the four engine mount fastening screws to 46 Nm (34 ft.lb). WARNING: Risk of damage! Do not turn the multiple-tooth nut -C-!
4. Install the transmission carrier and the hydraulic mount again. The M8 screws are tightened to 33 Nm (24 ft.lb).
5. Install engine carrier again. Tighten the four fastening screws to 65 Nm (48 ft.lb).
6. Remove the engine-transmission retainer plate. As soon as the engine has been fastened again, the car jack and the retainer plate can be removed.
7. Clip the guide tube of the oil dipstick into the socket.
8. Fit the rubber sleeve of the wiring harness again.
9. Re-connect engine control module. Start from the bottom and pay attention to the plug designations on the control module.
10. Connect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, insert the plug and lock the lateral slide.
11. Connect the ground point of the control module again and tighten the fastening nut.
12. Install the luggage compartment lining of the rear luggage compartment.
13. Screw air-conditioning compressor tight. Tighten the three fastening screws to 23 Nm (17 ft.lb).
14. Check the drive belt for damage and replace it if necessary. Fit the belt in its original running direction once more. The fitting sequence is shown in the following illustration. (Scheme 360)
15. Tighten the fuel line on the engine and the ground cable again. Make sure without fail to counter with a wrench when tightening the fuel line. The ground cable is tightened with 23 Nm (17 ft.lb).
16. Push the vacuum line for the brake booster in a straight line on to the flange, until the plug is heard to engage. Then install the grey snap ring again. Check that the line is seated properly by pulling on it gently.
17. Install the expansion tank of the power steering again. Check the sealing rings and replace, if necessary. Turn the lower adjusting ring to its original position and position the tank of the power steering. Press the tank downwards and at the same time turn the ring until the markings coincide. Then fill the tank with Pentosin according to the regulations.
18. Lay the B+ line of the alternator over the connecting bolt and tighten the fastening screw with 10 Nm (7.5 ft.lb). Close the protective cap of the B+ box.
19. Re-connect hot film mass air flow meter. Connect the connecting tube between the hot film mass air flow meter and the intake system and tighten the hose clamp.
20. Fit the oil filler line. Push the oil filler line back onto the flange and secure with a spring band clamp.
21. Engage the accelerator cable.
22. Refit clutch slave cylinder. Insert the cylinder back into the opening in the transmission. Tighten the fastening screw with 23 Nm (17 ft.lb).
23. Lay shift cables. Lay the shift cables in the engine compartment once more and clip them into the holder on the transmission. Then check once more that they are seated properly. Finally, press the shift cables back into the shift linkage. Check that the shift cables are installed correctly.
24. Screw heat shield tight. Fit the shield over the Tucker bolts and tighten the two sheetmetal nuts.
25. Screw the drive shafts on to the transmission again with new screws. The tightening torque is 39 Nm (29 ft.lb.) for the Boxster 2.7L and 81 Nm (60 ft.lb.) for the Boxster 3.2L. Subsequently remove the protective sheath.
26. Retighten cable. Fit the engine cable through the rear-axle support again and tighten the fastening nuts. Make sure to counter with a wrench when tightening. The tightening torque is 23 Nm (17 ft.lb).
27. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.
28. Detach threaded part -A- by pulling it off the nipple. (Scheme 370)
29. Insert the holder -C- into the threaded part -A- and screw both into the plug-in coupling -B- and tighten. (Scheme 371) Make sure to counter with a wrench when tightening. The tightening torque for the steering pressure line is 30 Nm (22 ft.lb.) (wrench size 15). The tightening torque for the steering return line is 40 Nm (30 ft.lb.) (wrench size 19).
30. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder. NOTE: The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly pulling or pressing.
31. The correct engagement of the plug-in couplings should be checked using the special tool 9623. To check this, insert the special tool 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.
32. Install the servo lines, the return line and the vacuum hose for the brake booster again and insert the retaining clip. CAUTION: Risk of damage! The fuel lines must not be kinked.
33. Connect the fuel lines. Re-connect the fuel lines on the vehicle underbody. The plug must engage audibly. Check correct seating by pulling gently. CAUTION: Danger of slipping hoses. Never apply a lubricant to the coolant hoses to make fitting easier!
34. Fit all the coolant hoses again. To make fitting easier, the coolant hoses can be wetted with water in the fitting area.
35. Check the coolant drain plug. If the drain plug is removed, it should be equipped with a new seal and re-mounted. The tightening torque for the screw is from 10 to 15 Nm (7.5 to 11 ft.lb).
36. Fit vent line again.
37. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ft.lb).
38. Move the exhaust system to its installation position again. In the process, replace all the seals at opened points. Tighten the three hexagon-head bolts again. Then tighten the screws on the exhaust manifold/catalytic converter with 25 Nm (18 ft.lb).
39. Connect the oxygen sensor cables. Connect the plugs and engage the holder in the rear-axle support.
40. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ft.lb).
41. Install stabilizer. To do so, insert the stabilizer on the left and right into the stabilizer mount and screw it tight to the two bearing surfaces. The fastening nuts on the mount are tightened with 46 Nm (34 ft.lb). The fastening screws on the bearing surfaces are tightened with 23 Nm (17 ft.lb).
42. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts with 65 Nm (48 ft.lb) and tighten the fastening screws with 46 Nm (34 ft.lb). Install the two diagonal braces into the vehicle. Tighten the fastening nuts to 65 Nm (48 ft.lb). NOTE: Vehicles with automatic headlight beam adjustment. Bear in mind that the angle sensor bracket (B) must be in contact at the bottom when the bolts on the rear-axle support (A) are tightened. Once installed, the control module must be calibrated with the PST 2. The headlights must then be reset. -A- Rear-axle support- -B - Angle sensor bracket- -C - Angle sensor- (Scheme 387)
43. Mount the underside panel.
44. Install the right and left wheel housing trims again.
45. Re-install the rear spoiler.
46. Install the rear spoiler again.
47. Re-position the trim of the rear luggage compartment and press in the fastening rivets. WARNING: Danger of short circuit! Pay attention to the correct seating of the rubber sleeve of the B+ lead!
48. Check the rubber sleeve. The rubber sleeve of the B+ lead must be fitted correctly and must not have slipped out of place.
49. Seal off the maintenance openings again. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening with 10 Nm (7.5 ft.lb).
50. Re-install the left seat. Tighten the four fastening nuts to 65 Nm (48 ft.lb).
51. Top up operating fluids. Check that all operating fluids (engine oil, Pentosin, coolant) are at the correct level. Both the coolant circuit and the power steering must be bled according to regulations.
52. Connect battery. Connect the battery terminals again and tighten. Subsequently, the fault memories of the vehicle must be read out and the theft codes may possibly have to be entered again. Re-teach the power windows.
53. Carry out a test drive. After the test drive, check that all the operating fluids are at the correct level. Check all circuits for leaks.
54. Fit convertible top again. To do so, take the mandrel out of the fixing bore.
55. Move the convertible top towards the rear until the linkage can be pushed back onto the pin. Then push the retaining clip into place.
56. Close convertible top. To do so, pull the tension bow towards the rear again and engage the tension cables again on the left and right.
57. Engage the cloth covering of the convertible top on the left and right into the retaining lugs.

MOUNTING INSTRUCTIONS

Note. The black sealant Loctite 5900 or Drei Bond Type 1209 are used for sealing the crankcase halves. The separation of the crankcase halves is made rather more difficult if Loctite 5900 is used.

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1. Undo ring-edge bolt. Unscrew the 25 hexagon-head bolts for this purpose.
2. Undo the third fastening point -(arrow)- on the crankcase half cylinder bank 4 - 6 from the engine holder. (Scheme 395)
3. Use a slotted screwdriver with a tip which is 14 mm wide and 250 mm long to separate the crankcase halves.
4. Insert the screwdriver in the lugs of the crankcase halves and separate the crankcase halves by tapping gently. Alternate the sides during separation. NOTE: Clean the crankcase halves using a nylon brush.
5. Clean the crankcase halves and then remove any residual sealant with a nylon brush.

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SPECIAL TOOLS

Note. Only Drei Bond Silicon Type 1209 and Loctite 5900 should be used for surface sealing. After application of surface seals (silicone bead), screw together within five minutes. Observe the expiry date of the surface seal.

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1. At the processing nozzle, cut off the first metering step at an angle. NOTE: Do not process the sealant too generously. No sealant should be pressed into the crankcase when screwing.
2. Apply a uniform bead of silicone approximately 1.5 mm wide to the cleaned sealing surface of the crankcase half of cylinder bank 4 to 6. The silicone bead should be applied as shown in the following illustration.
3. Position the crankcase halves carefully and evenly. The sealant bead must not be damaged during this procedure.
4. Screw the crankcase into place. Mount the crankcase with new screws. The tightening torque is 13 Nm (9.5 ft.lb). Observe the tightening sequence.
5. After tightening the crankcase halves, fasten the third fastening point between the crankcase half (cylinders 4 - 6) and special tool engine holder 9589.

Note. If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.

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1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. (Scheme 408) The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated position Boxster. The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Support for Tiptronic transmission with three M6 x 20 (2 ea.) and M8 x 25 (1 ea.) wood screws.
6. Fit complete retainer plate on the workshop jack. Drawing shows complete engine retainer plate fitted on the workshop jack.

Note. The engine is removed downwards complete with the manual transmission.

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1. Position the vehicle at the specified points on a lifting platform.
2. Open both the luggage compartment lids.
3. Cover the vehicle. Cover the vehicle with protective covers in such a way that the body can not be damaged.
4. Move convertible top or convertible-top compartment lid to service position. Open the convertible top until the convertible-top compartment lid is half open.
5. Detach cloth covering. Disengage the rear strip on the left and right sides of the cloth covering in downward direction.
6. Detach tension cables. Press the ball socket of the tension cable out of the ball head of the adjusting piece on the left and right.
7. Move convertible top to service position. To do so, press the tension bow of the convertible top towards the main bow, until it reaches its locking point.
8. Move the convertible-top compartment lid to service position and secure. Disengage the convertible-top compartment links at the extreme bottom. To do so, disengage the clips at the left and right and pull the links off the bolt.
9. Press the convertible-top compartment links forwards until the two bores coincide and a 5 mm mandrel can be pushed through.
10. Remove left-hand seat. For better accessibility, remove the left-hand seat of the car. Unscrew the four Torx screws, disconnect all the electrical plug connections and remove the seat.
11. Open the rear wall cover. To do so, remove the oddments tray behind the seats and remove the rear wall lining. Then undo the 6 fastening screws and the 2 fastening nuts. (Scheme 414) CAUTION: Risk of short circuit First remove the ground terminal. Cover the terminals. Never connect (short circuit) the terminals.
12. Disconnect battery. Before disconnecting, find out the relevant theft codes (e.g. radio) if necessary. At the battery, disconnect the ground terminal and remove the ground cable Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199496-S08906116372005101900000). Remove the rear spoiler. «REMOVING AND INSTALLING REAR SPOILER»(ref-199811-S17067956542005102000000).
13. Remove rear bumper. While doing so, pay attention to the connection for the number plate lighting. Refer to «REMOVING AND INSTALLING REAR SPOILER»(ref-199811-S17067956542005102000000).
14. Remove left and right wheel housing trims.
15. Remove the rear part of the underbody cover.
16. Lift the vehicle. Before lifting, check that all fastening points of the diagonal braces are easily accessible. Pay particular attention to the threaded part -C-. (Scheme 419)
17. Undo the fastening screw -C- and the collar nuts -D- and remove the diagonal braces -B- together with the holder -E-. (Scheme 420)
18. Remove stabilizer. To do so, unscrew the two fastening screws on the left and right of the two bearing surfaces and unscrew the stabilizer on the left and right from the links.
19. Detach rear cross member (aluminum V-member) on the body.
20. Undo the cable. Undo the engine cable on the rear-axle support. The cable must be countered with a suitable wrench and must not be twisted.
21. Release drive shafts. To do so, loosen and protect the fastening nuts on the transmission.
22. Unclip and detach the oxygen sensor plug connection from the holders of the rear-axle support. On an OBD II vehicle, additionally disconnect the oxygen sensor plug connection in the rear wing area. Press the heat shield aside and disconnect the plugs.
23. Remove rear mufflers. To do so, secure the rear mufflers with a transmission jack. Then undo the flange connection between the catalytic converters and the exhaust manifold. Undo the three hexagon-head bolts on the exhaust bracket. NOTE: When lowering, do not damage the oxygen sensors, cables and plugs. Attach protective sleeves around the oxygen sensor plugs.
24. Remove the front lining in the rear luggage compartment. Lever off plastic clips using a commercially available removal tool..
25. Remove the rear-axle support. Unscrew the four fastening screws and remove the rear-axle support to one side.
26. Drain coolant. To do so, remove the screw plug of the coolant circuit on the coolant guide housing. Collect coolant in a clean container.
27. Disconnect coolant hoses. Open the supply and return lines for coolant on the engine and pull them off. Then close all openings. Collect emerging coolant in a clean container. CAUTION: Danger of fire! Collect emerging fuel. Avoid ignition sources and naked flames.
28. Detach the fuel return line. Disconnect the fuel return line under the vehicle floor by pressing gently on the button and pull apart. Collect emerging fuel. Close off the open ends of the line immediately. Then open the holder on the body and remove the line.
29. Disconnect the steering lines. Remove the small undersealing on the left vehicle side (six plastic nuts). Disconnect the two hydraulic lines of the power steering on the vehicle floor. To do so, undo the threaded part and disconnect. Any emerging Pentosin must be collected.
30. Disengage the retaining clips for the power-assisted steering lines and the brake vacuum hose and remove the lines.
31. Disconnect the plug connection of the multifunction switch.
32. Disconnect plug from transmission socket. The plug must be turned anti-clockwise. Then pull off the plug.
33. Detach selector lever cable at deflection linkage and at the transmission support.
34. Disengage the accelerator cable. Remove the cover on the deflector box and disengage the accelerator cable.
35. Disconnect the electric plug on the hot film mass air flow sensor. Then disconnect the connecting hose between the hot film mass air flow sensor and the throttle body. To do so, disconnect the hose clamp on the hot film mass air flow sensor.
36. Press the spring band clamp on the oil filler hose apart and push it aside. Pull off the oil filler hose; heat, if necessary.
37. Disconnect the fuel supply hose. Make sure without fail to counter with a suitable wrench when doing this. Collect emerging residual fuel. Then disconnect the ground cable of the secondary air pump.
38. Disconnect vacuum line for the brake booster. To do so, remove the grey snap ring. Then push the inner sleeve -1- against the outer sleeve -2- and pull off both sleeves together in the direction of the arrow. (Scheme 441)
39. Disconnect B+ separator box. To do so, undo the hexagon nut in the separator box. Remove the cable and lay to one side.
40. Remove supply tank of the power steering system. To do so, suck fluid out as much as possible. Then open the bayonet lock on the bottom of the expansion tank and remove the tank. Close the opening in the servo pump with a clean plug. NOTE: In vehicles with air conditioning, points 42 to 45 must also be carried out. Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
41. Remove drive belt. Mark the running direction of the drive belt with a colored pen. Slacken the belt. Slacken belt by turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.
42. Undo the rear fastening screw of the air-conditioning compressor from above. The screw is positioned between the intake manifolds of the fifth and sixth cylinders.
43. Loosen air-conditioning compressor. To do so, undo the two front fastening screws -(arrows)-. (Scheme 446) Disconnect the electrical plug. NOTE: The air-conditioning compressor can be removed from the vehicle more easily if the engine has already been lowered.
44. Set the air-conditioning compressor with the hoses connected to one side or lift it out of the engine compartment and set it on a suitable base.
45. Remove the rear luggage compartment lining. To do so, lever out the rear fastening clips and remove the lining from the luggage compartment.
46. Disconnect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, raise the lock at the side and pull the plug out.
47. Remove the Tiptronic control module. Undo the three -fastening nuts- and pull off the control module plug.
48. Disconnect control module. Disconnect the plugs of the Tiptronic control module. At the same time, lock the ground point of the engine control module.
49. Disconnect engine control module. Open the topmost plug by actuating the side button and pull out. Remove the other plugs from the top down. To do so, press the locking button in and push the locking bar upwards.
50. Uncover the engine wiring harness. To do so, press the rubber sleeve on the luggage compartment rear wall inwards and guide the wiring harness towards the engine compartment, if the engine is to be lowered later.
51. Disconnect the plug connection at the guide tube of the oil dip stick. To do so, press the two tabs together and unclip the tube. NOTE: It is recommended to position the complete retainer plate using a transmission jack first. Only then should the workshop car jack be placed underneath. The support C1 should rest against the transmission oil pan under a slight pre-load. If necessary, fit the included spacer plate.
52. Place pre-assembled engine retainer plate with transmission support on the crankcase or transmission. CAUTION: Risk of damage When undoing the multi-tooth nut, the mount is destroyed!
53. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
54. Undo engine carrier. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
55. Lower the engine-transmission unit carefully. Ensure that there is sufficient clearance for the components. The engine wiring harness must be guided during the lowering procedure. WARNING: Risk of damage Only place the vehicle on its wheels or push it after the rear-axle support, the sheetmetal brace and both the diagonal braces have been installed.

Scheme 458

Scheme 459

SPECIAL TOOLS

Scheme 460

SPECIAL TOOLS

Note. If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.

Scheme 461

Scheme 462

Scheme 463

1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. (Scheme 464) The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated positions Boxster. The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Support for Tiptronic transmission with three M6 x 20 (2 ea.) and M8 x 25 (1 ea.) wood screws.
6. Fasten complete retainer plate on the workshop jack.

Scheme 464

Scheme 465

1. Check the fuel hose for correct routing. The fuel hose is routed behind the engine wiring harness.
2. When installing the rear-axle parts, it is essential to observe the correct sequence. The sheetmetal brace should be installed first, then the diagonal brace and finally the rear-axle support.
3. The V-brace must be fitted before the exhaust system is installed.
4. Finally, perform a suspension alignment.
5. Read out fault memory.

Note. In order to facilitate the fitting of the air-conditioning compressor, it should be moved back into its installation position during the running-in of the engine.

Scheme 466

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Scheme 494

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Scheme 508

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Scheme 511

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Scheme 514

Scheme 515

1. Lift the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time. When lifting, pay particular attention to the clearance between the rear-axle longitudinal support and the VarioCam cable. Place the air-conditioning compressor in its installation position at this stage.
2. Push the engine wiring harness through the bulkhead and into the luggage compartment before the final installation position is reached.
3. Install engine carrier again. Tighten the four fastening nuts to 65 Nm (48 ft.lb). WARNING: Risk of damage Do not turn the multiple-tooth nut -C-!
4. Install the transmission carrier and the hydraulic mount again. Tighten the M8 screws to 33 Nm (24 ft.lb) and the M10 screws to 65 Nm (48 ft.lb).
5. Remove the engine-transmission retainer plate. As soon as the engine has been fastened again, the car jack and the retainer plate can be removed.
6. Clip the guide tube of the oil dip stick into the socket.
7. Fit the rubber sleeve of the wiring harness again.
8. Re-connect engine control module. To do so, start at the bottom. Pay attention to the plug designations on the control module.
9. Re-connect and install the Tiptronic control module. Tighten the three fastening nuts.
10. Connect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, insert the plug and lock the lateral slide.
11. Connect the ground point of the control module again and tighten the fastening nut.
12. Install the luggage compartment lining of the rear luggage compartment.
13. Screw air-conditioning compressor tight. Tighten the three fastening screws to 23 Nm (17 ft.lb).
14. Check the drive belt for damage and replace it if necessary. Fit the belt in its original running direction once more. The fitting sequence is shown in the following illustration.
15. Tighten the fuel line on the engine and the ground cable again. Make sure without fail to counter with a wrench when tightening the fuel line. The ground cable is tightened to 23 Nm (17 ft.lb) and the fuel supply line to 30 Nm (22 ft.lb).
16. Push the vacuum line for the brake booster in a straight line onto the flange, until the plug is heard engaging. Then install the grey snap ring again. Check that the line is seated properly by pulling on it gently.
17. Install the expansion tank of the power steering again. Check the sealing rings and replace, if necessary. Turn the lower adjusting ring to its original position and position the tank of the power steering. Press the tank downwards and at the same time turn the ring until the markings coincide. Then fill the tank with Pentosin according to the regulations.
18. Lay the B+ line of the alternator over the connecting bolt and tighten the fastening screw to 10 Nm (7.5 ft.lb). Close the protective cap of the B+ box.
19. Re-connect hot film mass air flow meter. Connect the connecting tube between the hot film mass air flow meter and the intake system and tighten the hose clamp.
20. Attach oil filler neck. Push the oil filler neck back onto the flange and secure with a spring band clamp.
21. Engage the accelerator cable.
22. Engage selector lever cable at deflection lever and at the transmission support.
23. Position the plug at the transmission socket. Disconnect the plug and turn clockwise.
24. Re-connect the plug for the multifunction switch.
25. Screw the drive shafts to the transmission again. The tightening torque is 39 Nm (29 ft.lb). Then remove the protective sheaths.
26. Re-tighten cable. Fit the engine cables through the rear-axle support again and tighten the fastening nuts. Make sure to counter with a wrench when tightening. The tightening torque is 23 Nm (17 ft.lb).
27. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.
28. Detach threaded part -A- by pulling it off the nipple. (Scheme 494)
29. Insert the holder -C- into the threaded part -A- and screw both into the plug-in coupling -B- and tighten. (Scheme 495) Make sure to counter with a wrench when tightening. The tightening torque for the steering pressure line is 30 Nm (22 ft.lb) (wrench size 15). The tightening torque for the steering return line is 40 Nm (30 ft.lb) (wrench size 19).
30. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder. NOTE: The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly pulling or pressing.
31. The correct engagement of the plug-in couplings should be checked using the special tool 9623. To check this, insert the special tool 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.
32. Install the servo lines, the return line and the vacuum hose for the brake booster again and insert the retaining clip. CAUTION: Risk of damage. The fuel lines must not be kinked.
33. Connect the fuel lines. Re-connect the fuel lines on the vehicle floor. The connector must engage audibly. Check correct seating by pulling gently. CAUTION: Danger of slipping hoses. Never apply a lubricant to the coolant hoses to make fitting easier!
34. Fit all the coolant hoses again. To make fitting easier, the coolant hoses can be wetted with water in the fitting area.
35. Check coolant drain plug. If the drain plug is removed, it should be equipped with a new seal and re-mounted. The tightening torque for the screw is from 10 to 15 Nm (7.5 to 11 ft.lb).
36. Fit vent line again.
37. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ft.lb).
38. Move the exhaust system to its installation position again. In the process, replace all the seals at opened points. Tighten the three hexagon-head bolts again. Then tighten the screws on the exhaust manifold/catalytic converter with 25 Nm (18 ft.lb).
39. Connect oxygen sensors. Connect the plugs and engage the holder in the rear-axle support.
40. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ft.lb).
41. Install stabilizer. To do so, insert the stabilizer on the left and right into the stabilizer mount and screw it tight to the two bearing surfaces. The fastening nuts on the mount are tightened to 50 Nm (37 ft.lb). The fastening screws on the bearing surfaces are tightened to 23 Nm (17 ft.lb).
42. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts to 65 Nm (48 ft.lb) and tighten the fastening screws to 46 Nm (34 ft.lb). Install the diagonal braces into the vehicle. Tighten the fastening nuts to 65 Nm (48 ft.lb). NOTE: Vehicles with automatic headlight beam adjustment. Bear in mind that the angle sensor bracket (B) must be in contact at the bottom when the bolts on the rear-axle support (A) are tightened. Once installed, the control module must be calibrated with the System Tester PST 2. The headlights must then be reset. -A- Rear-axle support- -B - Angle sensor bracket- -C - Angle sensor- (Scheme 511)
43. Fit the underbody panel.
44. Install the right and left wheel housing trims again.
45. Re-install the rear spoiler.
46. Install the rear spoiler again.
47. Re-position the trim of the rear luggage compartment and press in the fastening rivets. WARNING: Risk of short circuit Pay attention to the correct seating of the rubber sleeve of the B+ lead!
48. Check the rubber sleeve. The rubber sleeve of the B+ lead must be fitted correctly and must not have slipped out of place.
49. Re-install the left seat. Tighten the four fastening screws to 65 Nm (48 ft.lb).
50. Top up operating fluids. Check that all operating fluids (engine oil, Pentosin, coolant) are at the correct level. Both the coolant circuit and the power steering must be bled according to regulations.
51. Connect battery. Connect the battery terminals again and tighten. Subsequently, the fault memories of the vehicle must be read out and the theft codes may possibly have to be entered again. Re-program the power windows.
52. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening to 10 Nm (7.5 ft.lb).
53. Carry out a test drive. After the test drive, check that all the operating fluids are at the correct level. Check all circuits for leaks.
54. Fit convertible top again. To do so, take the mandrel out of the fixing bore.
55. Move the convertible top towards the rear until the linkage can be pushed back onto the pin. Then push the retaining clip into place.
56. Close convertible top. To do so, pull the tension bow towards the rear again and engage the tension cables again on the left and right.
57. Engage the cloth covering of the convertible top on the left and right into the retaining lugs.

Note. If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.

Scheme 516

Scheme 517

Scheme 518

Scheme 519

1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. (Scheme 520) The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated position Boxster. The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Support for Tiptronic transmission with three M6 x 20 (2 ea.) and M8 x 25 (1 ea.) wood screws.
6. Fit complete retainer plate on the workshop jack.

Scheme 520

Note. The engine is removed downwards complete with the manual transmission.

Scheme 521

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1. Position the vehicle at the specified points on a lifting platform.
2. Open both the luggage compartment lids.
3. Cover the vehicle. Cover the vehicle with protective covers in such a way that the body can not be damaged.
4. Move convertible top or convertible-top compartment lid to service position. Open the convertible top until the convertible-top compartment lid is half open.
5. Detach cloth covering. Disengage the rear strip on the left and right sides of the cloth covering in downward direction.
6. Detach tension cables. Press the ball socket of the tension cable out of the ball head of the adjusting piece on the left and right.
7. Move convertible top to service position. To do so, press the tension bow of the convertible top towards the main bow, until it reaches its locking point.
8. Move the convertible-top compartment lid to service position and secure. Disengage the convertible-top compartment links at the extreme bottom. To do so, disengage the clips at the left and right and pull the links off the bolt.
9. Press the convertible-top compartment links forwards until the two bores coincide and a 5 mm mandrel can be pushed through them.
10. Remove left-hand seat. For better accessibility, remove the left-hand seat of the car. Unscrew the four internal-serration screws, disconnect all the electrical plug connections and remove the seat.
11. Open the rear wall cover. To do so, remove the oddments tray behind the seats and remove the rear wall lining. Then undo the 6 fastening screws and the 2 fastening nuts. See -arrows- in (Scheme 526). CAUTION: Danger of short circuit! First remove the ground terminal. Cover the terminals. Never connect (short circuit) the terminals.
12. Disconnect battery. Before disconnecting, find out the relevant theft codes (e.g. radio) if necessary. At the battery, disconnect the ground terminal and remove the ground cable Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199496-S08906116372005101900000). Remove the rear spoiler. «REMOVING AND INSTALLING REAR SPOILER»(ref-199811-S17067956542005102000000).
13. Remove rear bumper. While doing so, pay attention to the connection for the number plate lighting. Refer to «REMOVING AND INSTALLING REAR SPOILER»(ref-199811-S17067956542005102000000).
14. Remove left and right wheel housing trims.
15. Remove the rear part of the underbody cover.
16. Lift the vehicle. Before lifting, check that all fastening points of the diagonal braces are easily accessible. Pay particular attention to the threaded part -C-. (Scheme 531)
17. Undo the fastening screw -C- and the collar nuts -D- and remove the diagonal braces -B- together with the holder -E-. (Scheme 532)
18. Remove stabilizer.
19. To do so, unscrew the two fastening screws at each of the two bearing surfaces on the left and right.
20. Unscrew the stabilizer on the left and right of the links.
21. Detach rear cross member (aluminum V-member) on the body.
22. Undo the cable. Undo the engine cable on the rear-axle support. The cable must be countered with a suitable wrench and must not be twisted.
23. Release drive shafts. To do so, loosen and protect the fastening nuts on the transmission.
24. Unclip and detach the oxygen sensor plug connection from the holders of the rear-axle support. On an OBD II vehicle, additionally disconnect the oxygen sensor plug connection in the rear wing area. Press the heat shield aside and disconnect the plugs.
25. Remove rear mufflers. To do so, secure the rear mufflers with a transmission jack. Then undo the flange connection between the catalytic converters and the exhaust manifold. Undo the three hexagon-head bolts on the exhaust bracket. NOTE: When lowering, do not damage the oxygen sensors, cables and plugs. Attach protective sleeves around the oxygen sensor plugs.
26. Remove the front lining in the rear luggage compartment. Lever off plastic clips using a commercially available removal tool.
27. Remove the rear-axle support. Unscrew the four fastening screws and remove the rear-axle support to one side.
28. Drain coolant. To do so, remove the screw plug of the coolant circuit on the coolant guide housing. Collect coolant in a clean container.
29. Disconnect coolant hoses. Open the supply and return lines for coolant on the engine and pull them off. Then close all openings. Collect emerging coolant in a clean container. CAUTION: Danger of fire! Collect emerging fuel. Avoid ignition sources and naked flames.
30. Detach the fuel return line. Disconnect the fuel return line under the vehicle floor by pressing gently on the button and pull apart. Collect emerging fuel. Close off the open ends of the line immediately. Then open the holder on the body and remove the line.
31. Disconnect the steering lines. Remove the small undersealing on the left vehicle underside (six plastic nuts). Disconnect the two hydraulic lines of the power steering on the vehicle floor. To do so, undo the threaded part and disconnect. Any emerging Pentosin must be collected.
32. Disengage the retaining clips for the power-assisted steering lines and the brake vacuum hose and remove the lines.
33. Unscrew the heat shield on the transmission. To do so, unscrew the two fastening nuts and remove the plate.
34. Disengage shift cables on the transmission. Disengage the cables with the commercially available tool.
35. Detach the shift cables. Unclip the shift cables on the transmission mount. Then pull the shift cables upwards out of the engine compartment and set them aside. WARNING: Risk of damage When the clutch slave cylinder is removed, do not actuate the clutch again.
36. Uncouple clutch slave cylinder. To do so, unscrew the fastening screw and remove the clutch slave cylinder. Tie the cylinder with a wire.
37. Disconnect the electric plug on the hot film mass air flow sensor. Then disconnect the connecting hose between the hot film mass air flow sensor and the throttle body. To do so, disconnect the hose clamp on the hot film mass air flow sensor.
38. Open the spring band clamp on the oil filler hose and push it aside. Pull off the oil filler hose; heat, if necessary.
39. Disconnect the fuel supply hose. Make sure without fail to counter with a suitable wrench when doing this. Collect emerging residual fuel. Then disconnect the ground cable.
40. Disconnect vacuum line for the brake booster. To do so, remove the grey snap ring. Then push the inner sleeve -1- against the outer sleeve -2- and pull off both sleeves together in the direction of the arrow.
41. Disconnect B+ separator box. To do so, undo the nut in the separator box. Remove the cable and lay to one side.
42. Remove supply tank of the power steering system. To do so, suck fluid out as much as possible. Then open the bayonet lock on the bottom of the expansion tank and remove the tank. Close the opening in the servo pump with a clean plug. NOTE: In vehicles with air conditioning, points 44 to 47 must also be carried out. Never evacuate and open the air-conditioning circuit unless this is absolutely necessary.
43. Remove drive belt. Mark the running direction of the drive belt with a colored pen. Slacken the belt. Slacken belt by turning the tensioning pulley (wrench size 24 mm) clockwise, hold still and simultaneously take the belt off the drive pulleys.
44. Undo the rear fastening screw of the air-conditioning compressor from above. The screw is positioned between the intake manifolds of the fifth and sixth cylinders.
45. Loosen air-conditioning compressor. To do so, undo the two front fastening screws -(arrows)-. (Scheme 556) Disconnect the electrical plug. NOTE: The air-conditioning compressor can be removed from the vehicle more easily if the engine has already been lowered.
46. Set the air-conditioning compressor with the hoses connected to one side or lift it out of the engine compartment and set it on a suitable base.
47. Remove the rear luggage compartment lining. To do so, lever out the rear fastening clips and remove the lining from the luggage compartment.
48. Disconnect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, raise the lock at the side and pull the plug out.
49. Lock the ground point of the engine control module.
50. Unplug the engine control module. Open the topmost plug by actuating the side button and pull out. Remove the other plugs from the top down. To do so, press the locking button in and push the locking bar upwards.
51. Uncover the engine wiring harness. To do so, press the rubber sleeve on the luggage compartment rear wall inwards and guide the wiring harness towards the engine compartment, if the engine is to be lowered later.
52. Disconnect the plug connection at the guide tube of the oil dip stick. To do so, press the two tabs together and unclip the tube. NOTE: It is recommended to position the complete retainer plate using a transmission jack first. Only then should the workshop car jack be placed underneath. The support C1 should rest against the transmission oil pan under a slight pre-load. If necessary, fit the included spacer plate.
53. Place pre-assembled engine retainer plate with transmission support on the crankcase or transmission. CAUTION: Risk of damage When undoing the multi-tooth nut, the mount is destroyed!
54. Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
55. Undo the front engine carrier. To do so, unscrew the four fastening nuts.
56. Lower the engine-transmission unit carefully. Ensure that there is sufficient clearance for the components. The engine wiring harness must be guided during the lowering procedure. WARNING: Risk of damage Only place the vehicle on its wheels or push it after the rear-axle support, the sheetmetal brace and both the diagonal braces have been installed.

Scheme 565

Scheme 566

SPECIAL TOOLS

Scheme 567

SPECIAL TOOLS

Note. If the special tool 9592 is being used for the first time, (four) additional threaded holes must be applied.

Scheme 568

Scheme 569

Scheme 570

Scheme 571

Scheme 572

1. Lay the support plate 9592/1 on the rear of the retainer plate 9592 and fasten with four hexagon-head bolts M8 x 25.
2. Countersink the retainer plate at the designated bores -arrows- with a 9 mm drill bit. The support plate serves as the drilling template.
3. Drill through the countersunk bores on the retainer plate with a drill bit sized 6.8 mm and then cut an M8 thread.
4. Fasten the special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-head bolts M8 x 16 (bolt quality 10.9) at the designated positions Boxster. The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-head bolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Support for Tiptronic transmission with three M6 x 20 (2 ea.) and M8 x 25 (1 ea.) wood screws.
6. Fasten complete retainer plate on the workshop jack.

Scheme 573

1. Check the fuel hose for correct routing. The fuel hose is routed behind the engine wiring harness.
2. When installing the rear-axle parts, it is essential to observe the correct sequence. The sheetmetal brace should be installed first, then the diagonal brace and finally the rear-axle support.
3. The V-brace must be fitted before the exhaust system is installed.
4. Finally, perform a suspension alignment.
5. Read out fault memory.

Note. In order to facilitate the fitting of the air-conditioning compressor, it should be moved back into its installation position during the running-in of the engine.

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

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Scheme 580

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Scheme 582

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Scheme 606

Scheme 607

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

Scheme 613

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

1. Lift the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time. When lifting, pay particular attention to the clearance between the rear-axle longitudinal support and the VarioCam cable. Place the air-conditioning compressor in its installation position at this stage.
2. Push the engine wiring harness through the bulkhead and into the luggage compartment before the final installation position is reached.
3. Install engine carrier again. Tighten the four fastening nuts to 65 Nm (48 ft.lb). WARNING: Risk of damage Do not turn the multiple-tooth nut -C-!
4. Install the transmission carrier and the hydraulic mount again. Tighten the M8 screws to 33 Nm (24 ft.lb) and the M10 screws to 65 Nm (48 ft.lb).
5. Remove the engine-transmission retainer plate. As soon as the engine has been fastened again, the car jack and the retainer plate can be removed.
6. Clip the guide tube of the oil dip stick into the socket.
7. Fit the rubber sleeve of the wiring harness again.
8. Re-connect engine control module. To do so, start at the bottom. Pay attention to the plug designations on the control module.
9. Connect the plug connections (X3/1, X3/2 and X59) of the engine wiring harness. To do so, insert the plug and lock the lateral slide.
10. Connect the ground point of the control module again and tighten the fastening nut.
11. Install the luggage compartment lining of the rear luggage compartment.
12. Screw air-conditioning compressor tight. Tighten the three fastening screws to 23 Nm (17 ft.lb).
13. Check the drive belt for damage and replace it if necessary. Fit the belt in its original running direction once more. The fitting sequence is shown in the following illustration.
14. Tighten the fuel line on the engine and the ground cable again. Make sure without fail to counter with a wrench when tightening the fuel line. The ground cable is tightened to 23 Nm (17 ft.lb) and the fuel supply line to 30 Nm (22 ft.lb).
15. Push the vacuum line for the brake booster in a straight line onto the flange, until the plug is heard engaging. Then install the grey snap ring again. Check that the line is seated properly by pulling on it gently.
16. Install the expansion tank of the power steering again. Check the sealing rings and replace, if necessary. Turn the lower adjusting ring to its original position and position the tank of the power steering. Press the tank downwards and at the same time turn the ring until the markings coincide. Then fill the tank with Pentosin according to the regulations.
17. Lay the B+ line of the alternator over the connecting bolt and tighten the fastening screw to 10 Nm (7.5 ft.lb). Close the protective cap of the B+ box.
18. Re-connect hot film mass air flow meter. Connect the connecting tube between the hot film mass air flow meter and the intake system and tighten the hose clamp.
19. Attach oil filler neck. Push the oil filler neck back onto the flange and secure with a spring band clamp.
20. Re-fit clutch slave cylinder. Insert the cylinder back into the opening in the transmission. Tighten the fastening screw with 23 Nm (17 ft.lb).
21. Lay shift cables. Lay the shift cables in the engine compartment once more and clip them into the holder on the transmission. Then check once more that they are seated properly. Finally, press the shift cables back into the shift linkage. Check that the shift cables are installed correctly.
22. Screw heat shield tight. Fit the shield over the Tucker bolts and tighten the two sheetmetal nuts.
23. Screw the drive shafts on to the transmission again with new screws. The tightening torque for the Boxster 2.7L is 39 Nm (29 ft.lb) and 81 Nm (60 ft.lb) for the Boxster 3.2L. If monobloc drive shafts are installed in the Boxster 2.7L, the tightening torque is 81 Nm (60 ft.lb). Remove protective sheath.
24. Re-tighten cable. Fit the engine cable through the rear-axle support again and tighten the fastening nuts. Make sure to counter with a wrench when tightening. The tightening torque is 23 Nm (17 ft.lb).
25. Connect the power-assisted steering lines. To do so, tilt the holder on one side and pull out simultaneously.
26. Detach threaded part -A- by pulling it off the nipple. (Scheme 598)
27. Insert the holder -C- into the threaded part -A- and screw both into the plug-in coupling -B- and tighten. (Scheme 599) Make sure to counter with a wrench when tightening. The tightening torque for the steering pressure line is 30 Nm (22 ft.lb) (wrench size 15). The tightening torque for the steering return line is 40 Nm (30 ft.lb) (wrench size 19).
28. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder. NOTE: The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approx. 1 mm in axial direction by slightly pulling or pressing.
29. The correct engagement of the plug-in couplings should be checked using the special tool 9623. To check this, insert the special tool 9623 between the plug-in coupling and the screwed plug and tilt the tool slightly. The plug must not slide out.
30. Install the servo lines, the return line and the vacuum hose for the brake booster again and insert the retaining clip. CAUTION: Risk of damage The fuel lines must not be kinked.
31. Connect the fuel lines. Re-connect the fuel lines on the vehicle underbody. The connector must engage audibly. Check correct seating by pulling gently. CAUTION: Danger of slipping hoses. Never apply a lubricant to the coolant hoses to make fitting easier!
32. Fit all the coolant hoses again. To make fitting easier, the coolant hoses can be wetted with water in the fitting area.
33. Check coolant drain plug. If the drain plug is removed, it should be equipped with a new seal and re-mounted. The tightening torque for the screw is 10 Nm (7.5 ft.lb).
34. Fit vent line again.
35. Install rear-axle support again. The four fastening screws are tightened to 65 Nm (48 ft.lb).
36. Move the exhaust system to its installation position again. In the process, replace all the seals at opened points. Tighten the three hexagon-head bolts again. Then tighten the screws on the exhaust manifold/catalytic converter to 25 Nm (18 ft.lb).
37. Connect oxygen sensors. Connect the plugs and engage the holder in the rear-axle support.
38. Install the rear V-member. The four fastening screws are tightened to 65 Nm (48 ft.lb).
39. Install stabilizer. To do so, insert the stabilizer on the left and right into the stabilizer mount and screw it tight to the two bearing surfaces. The fastening nuts on the mount are tightened to 50 Nm (37 ft.lb). The fastening screws on the bearing surfaces are tightened to 23 Nm (17 ft.lb).
40. Install the sheetmetal brace into the vehicle. Tighten the hexagon nuts to 65 Nm (48 ft.lb.) and tighten the fastening screws to 46 Nm (34 ft.lb). Install the diagonal braces into the vehicle. Tighten the fastening nuts to 65 Nm (48 ft.lb). NOTE: Vehicles with automatic headlight beam adjustment. Bear in mind that the angle sensor bracket (B) must be in contact at the bottom when the bolts on the rear-axle support (A) are tightened. Once installed, the control module must be calibrated with the System Tester PST 2. The headlights must then be reset. -A- Rear-axle support- -B - Angle sensor bracket- -C - Angle sensor
41. Fit the underbody panel.
42. Install the right and left wheel housing trims again.
43. Re-install the rear spoiler.
44. Install the rear spoiler again.
45. Re-position the trim of the rear luggage compartment and press in the fastening rivets. WARNING: Risk of short circuit Pay attention to the correct seating of the rubber sleeve of the B+ lead!
46. Check the rubber sleeve. The rubber sleeve of the B+ lead must be fitted correctly and must not have slipped out of place.
47. Seal off the maintenance openings again. Seal off the upper and rear maintenance openings again. Tighten the seven fastening screws and the two fastening nuts of the rear maintenance opening to 10 Nm (7.5 ft.lb).
48. Re-install the left seat. Tighten the four fastening nuts to 65 Nm (48 ft.lb).
49. Top up operating fluids. Check that all operating fluids (engine oil, Pentosin, coolant) are at the correct level. Both the coolant circuit and the power steering must be bled according to regulations.
50. Connect battery. Connect the battery terminals again and tighten. Subsequently, the fault memories of the vehicle must be read out and the theft codes may possibly have to be entered again. Re-programme the power windows.
51. Carry out a test drive. After the test drive, check that all the operating fluids are at the correct level. Check all circuits for leaks.
52. Fit convertible top again. To do so, take the mandrel out of the fixing bore.
53. Move the convertible top towards the rear until the linkage can be pushed back onto the pin. Then push the retaining clip into place.
54. Close convertible top. To do so, pull the tension bow towards the rear again and engage the tension cables again on the left and right.
55. Engage the cloth covering of the convertible top on the left and right into the retaining lugs.

REMOVING DRIVE BELT

REMOVAL PROCEDURE FOR DRIVE BELT

INSTALLING DRIVE BELT

INSTALLATION PROCEDURE FOR DRIVE BELT

Scheme 619

REMOVAL AND INSTALLATION PROCEDURE OF DEFLECTION ROLLERS

Scheme 620

REMOVAL AND INSTALLATION PROCEDURE OF DEFLECTION ROLLERS

Scheme 621

SPECIAL TOOLS

Scheme 622

Scheme 623

Removing throttle body with intake distributor

Removing supply tank of power steering system

Separating steering pressure line and steering return line on underbod

Loosening steering return line in engine compartment

Separating steering return line from supply tank using tool

Loosening hydraulic pump and steering supply line in engine compartment

REMOVAL PROCEDURE OF BELT TENSIONER

Scheme 624

REMOVAL AND INSTALLATION PROCEDURE OF BELT TENSIONER

Scheme 625

DISASSEMBLY AND ASSEMBLY PROCEDURE OF BELT TENSIONER

Scheme 626

SPECIAL TOOL

The connecting-rod bearing caps must always remain allocated to the respective connecting rods and must never be interchanged.

Recommendation: After disassembly, immediately re-join the connecting-rod bearing cap and connecting rod or mark them on the sides with an electric scribing tool (e.g. with the cylinder designation). Never mark these parts with sharp objects such as pin punches or number embossing tools.

DISASSEMBLY AND ASSEMBLY PROCEDURE OF BEARING HOUSING WITH CRANKSHAFT (1 OF 2)

Scheme 627

DISASSEMBLY AND ASSEMBLY PROCEDURE OF BEARING HOUSING WITH CRANKSHAFT (2 OF 2)

FITTING PISTONS AND CONNECTING RODS

Prepare pistons and connecting rods for installation in the crankcase half of cylinders 1 - 3.

Scheme 628

Scheme 629

REMOVAL AND INSTALLATION PROCEDURE FOR PISTONS AND CONNECTING RODS

Scheme 630

Scheme 631

Scheme 632

Scheme 633

Scheme 634

Scheme 635

Scheme 636

Scheme 637

Scheme 638

Scheme 639

Scheme 640

Scheme 641

Scheme 642

Scheme 643

Scheme 644

Scheme 645

Scheme 646

Scheme 647

Scheme 648

1. Fasten cylinder housing half, cyl. 1-3, in conjunction with mounting elements 9590 to engine holder 9589.
2. Clean bearing housing support surface, particularly in area of oil duct. Check dowel sleeves for correct seating.
3. Installation of the compete bearing housing in the crankcase half, cylinders 1-3. As the bearing housing is heavy, it should be installed using a workshop crane. Carefully and in stages, lower bearing housing with fitted holder 9607 and workshop crane towards the dowel sleeves (2 ea.), observing the following points: To aid in guiding, screw two pan head screws approx. 3 turns into the bearing housing from below. Just before reaching the final installation position, pull the loosened intermediate-shaft flange out of the housing area and rotate the flange so that the two flange lugs that are spaced closest together face upwards. After lowering, check whether there is sag in the upper chain area or sufficient lever travel exists. Lift the bearing housing and check the chain installation if necessary. Remove two cap head screws (guide aid).
4. For the following assembly procedure - piston installation, cylinders 1, 2 and 3 - the crankcase half and bearing housing unit must be held by at least two screwed connections. For this purpose, fasten two original cylinder head screws and plastic spacer sleeves, special tool 9613, from below. Tightening torque: 30 Nm (22 ft.lb) Use Torx screwdriver insert T50.
5. Turn crankcase by 90° on the assembly support. Cylinders 1, 2 and 3 face upwards.
6. Fit belt pulley. Screw in fastening screw by hand.
7. Turn crankshaft clockwise until the bore U4 on the pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
8. Remove preassembled connecting rod with piston of cylinder 1 from the assembly fixture.
9. Align the gaps of the piston rings offset by 120°.
10. Place piston with connecting rod in installation position.
11. Tighten piston ring clamp and fit piston with connecting rod. NOTE: Generously coat the piston and restraining strap with engine oil before fitting the piston.
12. Use the handle of a hammer to tap the piston into the cylinder while firmly pressing on the edge of the restraining strap. Use protective gloves. NOTE: The piston must be fitted in the cylinder carefully and with feeling. If the resistance increases, immediately interrupt the assembly process. Reposition the piston ring restraining strap and repeat the assembly operation.
13. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9598).
14. Turn crankcase by 90° to the left. Make sure the bearing shell is correctly seated in the connecting rod. The fixing lugs point to the oil pan.
15. Fit end caps. Lubricate bearing shells. The recesses of the connecting-rod bearing twist lock must face each other.
16. Tightening specification: Oil thread and contact surface. 1. Initial tightening 20 Nm (15 ft.lb) To facilitate subsequent checks it is recommended that, after initial tightening, the screw heads be marked with a colored pen. 2. Final tightening 1 x 90° turn Use 10 mm socket wrench insert (double hexagon).
17. Fitting piston and connecting rod in cylinder 2. Rotate crankshaft clockwise until bore U5 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
18. Prepare preassembled connecting rod of cylinder 2 for installation. Perform the following assembly steps as described from Steps 8 to 16 .
19. Fitting piston and connecting rod in cylinder 3 Rotate crankshaft clockwise until bore U6 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
20. Prepare preassembled connecting rod of cylinder 3 for installation. Perform the following assembly steps as described from Steps 8 to 16 . NOTE: Leave crankshaft at position U6 after fitting the piston and connecting rod in cylinder 3. This position is necessary for subsequent fitting of the piston of cylinder 6.
21. Remove belt pulley.

FITTING PISTONS ON CYLINDER BANK 4 - 6

Note. The crankcase half of cylinder bank 4 - 6 must be fitted before installation of the pistons.

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

Scheme 658

Scheme 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

Scheme 686

1. Thoroughly clean sealing surface of the crankcase half of cylinder bank 1 - 3.
2. Ensure that the profile seals on the oil separator and the two seals on the coolant duct are seated correctly.
3. Apply a uniform bead of silicone approximately 1.5 mm wide to the cleaned sealing surface of the crankcase half of cylinder bank 4-6.
4. Place special tool 9645 on the receiving bore of the oil pump and turn the knob clockwise until the centering mandrel is braced in the crankcase half.
5. Before fitting the crankcase half, have a second person pull the drive chain out of the chain space using a wire.
6. Do not damage the sealing bead when setting the crankcase half in place.
7. Fasten crankcase half. Tightening torque: 13 Nm (10 ft.lb). Remove emerging silicone material.
8. Turn the centering mandrel anti-clockwise and remove. Remove silicone residue.
9. Remove special tool 9613.
10. Fit belt pulley. Screw in fastening screw by hand. Cylinder bank 4 - 6 faces upward. Bore U6 on the belt pulley must be aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595. NOTE: Fixing of the belt pulley is absolutely necessary in order to ensure precise fitting of the pistons.
11. Align connecting rod of cylinder 6. Insert centering mandrel, special tool 9608, in the assembly bore. NOTE: The centering mandrel remains in the eye of the connecting rod until the piston contacts the centering mandrel during fitting.
12. Install piston of cylinder 6. Check whether the piston pin circlip is present and was fitted correctly (flywheel side). The piston circlip opening must lie opposite the groove in the piston. Before installation, check whether the assembly tube (2) can be moved easily in the piston; remove burr if necessary.
13. Move piston to installation position, position the piston ring restraining strap and insert the piston. NOTE: Generously coat the piston, cylinder and restraining strap with engine oil before fitting the piston.
14. Use the handle of a hammer to tap the piston into the cylinder while firmly pressing on the edge of the restraining strap. Use protective gloves. NOTE: The piston must be fitted in the cylinder carefully and with feeling. If the resistance increases, immediately interrupt the assembly process. Reposition the piston ring restraining strap and repeat the assembly operation.
15. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9698) to the centering mandrel stop.
16. Carefully withdraw the centering mandrel and push the piston down to the stop.
17. Align piston and connecting rod again using the centering mandrel.
18. Push in piston pin as far as it will go using the pressure pin of special tool 9602.
19. Prepare piston pin circlip for fitting on the piston. It is important to pre-fit the circlip on a firm surface. The circlip must be pre-fitted only immediately prior to fitting on the piston pin eye. Manually insert the new circlip into the conical part of the assembly sleeve, special tool 9603. Place assembly sleeve 9603 onto the assembly tube of special tool 9602. Use assembly aid, special tool 9500/3, to slide the circlip from the conical sleeve into the assembly tube. Remove assembly sleeve 9500/3 and visually inspect the correct position of the circlip in the assembly tube. Carefully insert the pressure pin (1) of special tool 9602 into the assembly tube (2) until it contacts the piston pin circlip. The circlip can pop out of the assembly tube in the case of improper handling - danger of injury!
20. Carefully insert the complete unit, consisting of assembly tube with pressure pin, into the crankcase assembly bore. Press or position the assembly tube against the crankcase. Turn the assembly tube to move the piston pin circlip to the correct position. The piston circlip opening should lie opposite the groove in the piston for fitting. Mark the assembly tube. Move the piston pin circlip to the correct installation position by briefly and forcefully striking the palm against the handle of the pressure pin. Move the piston pin circlip to its installation position by briefly and forcefully striking the palm against the star knob of the pressure pin.
21. Visually inspect correct seating of the piston pin circlip, for example, with a shop-made electric torch with mirror. Drawing shows a torch with adjustable mirror.
22. Fitting piston in cylinder 5. Advance the crankshaft clockwise until bore U5 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin.
23. Perform the following assembly steps for piston installation in cylinder 5 as described from Steps 11 to 21 . Deviating assembly steps as from Step 24 .
24. A spacer sleeve (3) is additionally required when fitting the piston pin circlip in the piston of cylinder 5.
25. Fitting piston in cylinder 4. Advance the crankshaft clockwise until bore U4 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin.
26. Perform the following assembly steps for piston installation in cylinder 4 as described from Steps 11 to 21 . Deviating assembly steps as from Step 27 .
27. Two spacer sleeves (3 + 4) are additionally required when fitting the piston pin circlip in the piston of cylinder 4.
28. After fitting the pistons, fit a screw plug and new sealing ring in the assembly bore. Use a 12 mm hexagon socket wrench insert. Tightening torque: 80 Nm (59 ft.lb)
29. Fit guide rails of cylinder bank 1 - 3 (flywheel side); fit guide rails in correct position. View from the belt pulley side View from the flywheel side
30. Fit guide rails of cylinder bank 4-6 (pulley side); fit guide rails in correct position. View from the belt pulley side View from the belt pulley side
31. Fit oil pump with coolant guide housing. See «REMOVING AND INSTALLING OIL PUMP WITH COOLANT GUIDE HOUSING»(ref-199829-S41897340122005102100000) .
32. Fit intermediate shaft flange. Grease sealing ring in area of intermediate shaft flange. Grease receiver bore in area of the crankcase. Carefully press in the intermediate flange. Screw in new micro-encapsulated hexagon-head bolts M6 x 20 (3 ea.). Tightening torque: 10 Nm (7.5 ft.lb) Tighten locknut with the socket wrench, special tool 9110. For this purpose, hold with a slotted screwdriver 7.0 x 1.1 at the slotted threaded pin. Tightening torque: 10 Nm (7.5 ft.lb). Further assembly instructions see «REMOVING AND INSTALLING SEALING RING FOR INTERMEDIATE SHAFT»(ref-199829-S03103967682005102100000) .
33. Fit belt pulley.

Note. Check whether there are foreign objects in the drive belt grooves of the pulley and remove them if necessary.

Tighten hexagon-head bolt using the socket wrench insert 9594; simultaneously hold with retaining device 9593.

Tightening torque: 50 Nm (37 ft.lb)

Scheme 687

Scheme 688

REMOVING AND INSTALLING CRANKSHAFT SEALING RING - FLYWHEEL SIDE

Note. On vehicles with Tiptronic transmission, disconnect the battery, as the starter must be removed to separate the torque converter from the drive plate. Note the work instructions for disconnecting and reconnecting the battery. Disconnect the battery, see WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY . Remove Tiptronic transmission. Refer to REMOVING AND INSTALLING TIPTRONIC TRANSMISSION . Remove manual transmission. Refer to REMOVING AND INSTALLING TRANSMISSION G 86 . With the engine/transmission unit removed, uncouple the transmission.

Scheme 689

SPECIAL TOOLS

REMOVING CRANKSHAFT SEALING RING

Note. In order to avoid deforming the thrust plate housing, always loosen screws in several stages and in diametrically opposite sequence.

Scheme 690

Scheme 691

1. Remove the clutch pressure plate including clutch drive plate. Unscrew 6 M8 x 16 pan-head screws crossways in several stages. Remove the thrust plate, including the drive plate. Refer to «REMOVING AND INSTALLING THE CLUTCH PEDAL»(ref-199502-S31571891752005101900000). NOTE: Make sure not to damage the crankshaft flange when installing and removing the double-mass flywheel (DMF) or Tiptronic drive plate!
2. Remove the double-mass flywheel (manual transmission) or the drive plate for the torque converter (Tiptronic). Unscrew 8 M10 x 1 x 50 pan-head screws for the DMF or M10 x 1 x 25 in the case of the drive plate, remove DMF or drive plate. To counter, fasten toothed segment 9538/1 to the crankcase using an M12 x 50 hexagon-head bolt (fine thread). (Scheme 695) NOTE: Never use an abrasive or polishing cloth or brushes with metal bristles on the sealing surface of the crankshaft flange!
3. Carefully remove small edges or burrs on the chamfer of the crankshaft flange with an oilstone. Then, carefully degrease the crankshaft journal and crankcase bore (e.g. using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone). Blow dry using a low air pressure (0.5 bar) or ventilate. NOTE: The serial spindle sealing ring is pressed 11 mm in, measured from the end of the flange. The new sealing ring is pressed 13 mm in using the special tool insertion tool 9699 in order to generate a new running track. If the crankshaft flange is corroded, clean it as follows: Press the old crankshaft sealing ring in further with the special tool insertion tool 9699 in the same way as you would install a new sealing ring. Clean the crankshaft flange with a special metal-polishing pad (e.g. Never Dull, available in car and motor bike accessory stores). Then, carefully degrease the flange (e.g. using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone). Replace the crankshaft sealing ring as described below.
4. Spot drill the crankshaft sealing ring on the front -arrow- with a 3 mm drill bit, grease the drill bit beforehand. (Scheme 696)
5. Screw sheetmetal screw (5 x 20) with washer approx. 5 mm into the bore.
6. Pull out the sealing ring with the puller 9237 -arrow-. If necessary, clean crankshaft flange again.

Scheme 692

INSTALLING THE CRANKSHAFT SEALING RING

Note. The tools should be thoroughly examined for any burred spots each time a sealing ring is fitted. Even minor damage to the tool can damage the micro sealing lips of the new sealing ring! The illustrations of the special tools below show their use with the engine removed and on the assembly support. Their use with the engine installed is identical.

Scheme 693

Scheme 694

Scheme 695

1. Small burred spots or damaged areas on the tools can be eliminated with a nail file, then pull off with a fine abrasive or polishing cloth. Remove residual dirt on the tools, e.g. using solvent naphtha or acetone.
2. Check crankshaft installation position. To do this, insert special tool measuring mandrel 9699/1 across the crankshaft flange into the fitting bore of the crankcase. (Scheme 698) The measuring mandrel must be placed with slight resistance in the bore. If the measuring mandrel cannot be positioned, the engine must be replaced. NOTE: The crankshaft sealing ring must not be oiled or greased. The micro sealing lips, in particular, are so sensitive that even the smallest contact can cause damage. Coat only the crankshaft case bore with new oil.
3. Coat the crankshaft case bore with new engine oil and slide the new crankshaft sealing ring over the crankshaft flange.
4. Fit insertion tool 9699 between the two internal M8 pan-head screws, (hexagon socket a/f 8) -with hexagon socket wrench insert- on the crankshaft flange and fasten it. The crankshaft flange's dowel pin must sit in the bore of the device.
5. To position the crankshaft sealing ring correctly on the crankshaft flange, turn an open-end/ring wrench in a clockwise direction as far as it will go on the hexagon (a/f 19) of the device. (Scheme 700) Then remove the tool by releasing the pan-head screws.
6. Install the DMF or drive plate. Make sure that the crankshaft flange is not damaged.
7. Install the clutch pressure plate and drive plate.
8. Refit or install the transmission.
9. Install the engine/transmission unit if necessary.

Scheme 696

Scheme 697

SPECIAL TOOLS

Prepare pistons and connecting rods for installation in the crankcase half of cylinders 1-3.

Scheme 698

Scheme 699

REMOVAL AND INSTALLATION PROCEDURE FOR PISTONS AND CONNECTING RODS

Scheme 700

Scheme 701

Scheme 702

Scheme 703

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

1. Fasten crankcase half, cylinders 1 - 3, in conjunction with mounting elements 9590 to engine holder 9589.
2. Clean bearing housing support surface, particularly in area of oil duct. Check dowel sleeves for correct seating.
3. Installation of the complete bearing housing in the crankcase half, cylinders 1-3. As the bearing housing is heavy, it should be installed using a workshop crane. Carefully and in stages, lower bearing housing with fitted holder 9607 and using a workshop crane towards the dowel sleeves (2 ea.), observing the following points: To aid in guiding, screw two cylinder head screws approx. 3 turns into the bearing housing from below. Just before reaching the final installation position, pull the loosened intermediate-shaft flange out of the housing area and rotate the flange so that the two flange lugs that are spaced closest together face upwards. After lowering, check whether there is sag in the upper chain area or sufficient lever travel exists. Lift the bearing housing and check the chain installation if necessary. Remove two cylinder head screws (guidance aid).
4. For the following assembly procedure - piston installation, cylinders 1, 2 and 3 - the crankcase half and bearing housing unit must be held by at least two screw connections. For this purpose, fasten two original cylinder head screws and plastic spacer sleeves, special tool 9613, from below. Tightening torque 30 Nm (22 ft.lb). Use Torx screwdriver insert T50 or T55.
5. Turn crankcase by 180° on the assembly support. Cylinders 1, 2 and 3 face upwards.
6. Fit belt pulley. Screw in fastening screw by hand.
7. Turn crankshaft clockwise until the bore U4 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
8. Remove preassembled connecting rod with piston of cylinder 1 from the assembly fixture.
9. Align the gaps of the upper piston rings offset by 180°.
10. Tighten piston ring clamp and fit piston in the cylinder bore with connecting rod.
11. Place piston with connecting rod in installation position. NOTE: Generously coat the piston and restraining strap with engine oil before fitting the piston.
12. Use the handle of a hammer to tap the piston into the cylinder while firmly pressing on the edge of the restraining strap. Use protective gloves. NOTE: The piston must be fitted in the cylinder carefully and with feeling. If the resistance increases, immediately interrupt the assembly process. Reposition the piston ring restraining strap and repeat the assembly operation.
13. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9598).
14. Turn crankcase by 180°. Make sure the bearing shell is correctly seated in the connecting rod. The fixing lugs point to the oil pan.
15. Fit end caps. Lubricate bearing shells. The recesses of the connecting-rod bearing twist lock must face each other.
16. Tightening specification: Oil thread and contact surface. Initial tightening 20 Nm (15 ft.lb.) To facilitate subsequent checks it is recommended that the screw heads be marked with a colored pen after initial tightening. Final tightening 1 x 90° turn Use 10 mm socket wrench insert (double hexagon).
17. Fitting piston and connecting rod in cylinder 2 Turn crankcase by 180°. Turn crankshaft clockwise until the bore U5 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
18. Prepare preassembled connecting rod with piston of cylinder 2 for installation. Perform the following assembly steps as described from Steps 8 to 16 .
19. Fitting piston and connecting rod in cylinder 3 Rotate crankshaft clockwise until bore U6 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
20. Prepare preassembled connecting rod with piston of cylinder 3 for installation. Perform the following assembly steps as described from Steps 8 to 16 . NOTE: Leave crankshaft at position U6 after fitting the piston and connecting rod in cylinder 3. This position is necessary for subsequent fitting of the piston of cylinder 6.
21. Remove belt pulley.

Note. The crankcase half of cylinder bank 4-6 must be fitted before installation of the pistons.

Scheme 721

Scheme 722

Scheme 723

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735

Scheme 736

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

Scheme 750

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

Scheme 758

Scheme 759

Scheme 760

Scheme 761

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

1. Thoroughly clean sealing surface of the crankcase half of cylinder bank 1-3.
2. Ensure that the profile seals on the oil guide and the two seals left and right of the coolant duct are seated correctly.
3. Place centering mandrel, special tool 9645, on the take-up bore of the oil pump and turn the star knob clockwise until the centering mandrel is braced in the crankcase half (oil pressure builds up in centering mandrel).
4. Apply a uniform bead of silicone approximately 1.5 mm wide to the cleaned sealing surface of the crankcase half of cylinder bank 4-6.
5. Before fitting the crankcase half, have a second person pull the drive chain out of the chain space using a wire.
6. Carefully set the crankcase half in place so that the sealing bead is not damaged.
7. Fasten crankcase half. Tightening torque 13 Nm (10.0 ft.lb). Refer to «DISASSEMBLING AND ASSEMBLING CRANKCASE HALVES, ENGINE M96/20, M96/21, M96/22»(ref-199829-S39540737862005102100000) . Immediately remove silicone material emerging in the area of the oil pan sealing surface.
8. Relieve centering mandrel. Turn star knob anti-clockwise (oil pressure drops) and remove centering mandrel. Remove silicone residue.
9. Fasten engine holder, special tool 9589, to the crankcase half of cylinder 4-6 (3rd fastening point).
10. Remove plastic spacer sleeves, special tool 9613.
11. Fit belt pulley. Screw in fastening screw by hand. Cylinder bank 4-6 faces upward. Bore U6 on the belt pulley must be aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595. NOTE: Fixing of the belt pulley is absolutely necessary in order to ensure precise fitting of the pistons.
12. Unscrew plug for piston pin assembly bore. Use a 12 mm hexagon socket wrench insert.
13. Fasten centering aid, special tool 9602/2, with two countersunk screws with crosshead (M6 x 20) on the crankcase.
14. Align connecting rod of cylinder 6. Insert centering mandrel, special tool 9608, in the assembly bore. NOTE: The centering mandrel remains in the eye of the connecting rod until the piston contacts the centering mandrel during fitting.
15. Install piston of cylinder 6. Check whether the piston pin circlip is present and was fitted correctly (flywheel side). Before installation, check whether the assembly tube (2) can be moved easily in the piston eye; remove burr if necessary.
16. Align the gaps of the piston rings offset by 120°. Position piston ring clamp and fit piston. Piston in installation position NOTE: Generously coat the piston, cylinder and restraining strap with engine oil before fitting the piston.
17. Use the handle of a hammer to tap the piston gently into the cylinder while firmly pressing on the edge of the restraining strap. Use protective gloves. NOTE: The piston must be fitted in the cylinder carefully and with feeling. If the resistance increases, immediately interrupt the assembly process. Reposition the piston ring restraining strap and repeat the assembly operation.
18. Centre the piston in the cylinder bore and carefully push it down with the assembly aid (special tool 9698) to the centering mandrel stop.
19. Carefully withdraw the centering mandrel and push the piston down to the stop.
20. Align piston and connecting rod again using the centering mandrel.
21. Push in piston pin as far as it will go into the piston using the pressure pin of special tool 9602.
22. Prepare piston pin circlip for fitting on the piston. It is important to pre-fit the circlip on a firm surface. The circlip must be pre-fitted only immediately prior to fitting on the piston pin eye. Manually insert the new circlip into the conical part of the assembly sleeve, special tool 9603/1. Place assembly sleeve 9603/1 onto the assembly tube of special tool 9602. Use assembly aid, special tool 9500/3, to slide the circlip from the conical sleeve into the assembly tube. Remove assembly sleeve 9603/1 and visually inspect the correct position of the circlip in the assembly tube. CAUTION: Danger of injury if circlip springs out! Check position of the circlip only by visual inspection of the assembly tube from the side.
23. Push assembly tube through the centering piece into the crankcase assembly bore with the circlip fitted.
24. Carefully and gently insert the pressure pin until it contacts the piston pin circlip. NOTE: When inserting the pressure pin, the plastic ring on the pressure pin may touch the belt pulley. Either rework the plastic ring or remove the belt pulley briefly.
25. Move the piston pin circlip to its installation position by briefly and forcefully striking the palm of your hand against the star knob of the pressure pin.
26. Visually inspect correct seating of the piston pin circlip, for example, with a shop-made electric torch with mirror. Drawing shows a torch with adjustable mirror
27. Fitting piston in cylinder 5. Advance the crankshaft clockwise until bore U5 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin.
28. Perform the following assembly steps for piston installation in cylinder 5 as described from Steps 14 to 26 . A spacer sleeve (3) is additionally required when fitting the piston pin circlip in the piston of cylinder 5.
29. Fitting piston in cylinder 4. Advance the crankshaft clockwise until bore U4 on the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin.
30. Perform the following assembly steps for piston installation in cylinder 4 as described from Steps 14 .
31. Two spacer sleeves (3 + 4) are additionally required when fitting the piston pin circlip in the piston of cylinder 4.
32. Remove centering aid 9602/2.
33. Visually inspect correct seating of the piston pin circlip on the piston of cylinder 4. NOTE: If the piston, piston pin or piston pin circlip are incorrectly assembled, the corresponding piston can be pulled out of the cylinder as follows. Degrease Centre of piston crown. Coat suitable plastic mandrel with instant adhesive. Allow the adhesive to cure. Pull out piston. Remove plastic mandrel immediately.
34. After fitting the pistons, fit a screw plug and new sealing ring in the assembly bore. Use a 12 mm hexagon socket wrench insert. Tightening torque 80 Nm (59 ft.lb).
35. Fit guide rail and tensioning rail of cylinder bank 1-3 (flywheel side); fit guide rails in correct position. View from the belt pulley side View from the flywheel side
36. Fit guide rails and tensioning rails of cylinder bank 4-6 (flywheel side); fit guide rails in correct position. View from the belt pulley side View from the belt pulley side
37. Fit oil pump with coolant guide housing Assembly instructions: refer to «REMOVING AND INSTALLING OIL PUMP WITH COOLANT GUIDE HOUSING»(ref-199829-S41897340122005102100000) .
38. Fit intermediate-shaft flange. Grease sealing ring in area of intermediate-shaft flange. Grease take-up bore in area of the crankcase. Carefully press in the intermediate flange. Screw in new micro-encapsulated hexagon-head bolts M6 x 20 (3 ea.). Tightening torque 10 Nm (7.5 ft.lb). Tighten lock nut with the socket wrench, special tool 9110. For this purpose, hold with a slotted screwdriver 7.9 x 1.1 at the slotted threaded pin. Tightening torque 11 Nm (8.0 ft.lb).
39. Fit belt pulley. NOTE: Check whether there are foreign objects in the drive belt grooves of the belt pulley and remove them if necessary.

Tighten hexagon-head bolt using the socket wrench insert 9594; simultaneously hold with retaining device 9593.

Tightening torque 50 Nm (37 ft.lb)

Scheme 767

Final tightening: 1 x 90° turn

Scheme 768

The installation of the pistons for engine type M96/22 (2.7L) is the same as for the Boxster S (3.2L), described on REMOVING AND INSTALLING PISTONS - BOXSTER S .

Only the centering aid, special tool 9602/4, must be used for fitting pistons on cylinder bank 4 - 6.

Distinguishing characteristic

Thickness of centering aid 9602/4 8 mm.

Thickness of Boxster S centering aid 9602/2 10 mm.

Scheme 769

CHECKING PISTON WEAR

1. Clean the removed pistons with solvent naphtha. To identify the dimensional group (punched on the piston crown), carbon deposits must be carefully removed, e.g. with a brass brush.
2. Check the piston diameter -D- at the piston skirt using an external micrometer. The measurement -X- is made at 16 mm from the bottom edge of the skirt.

Scheme 770

Note. The piston must be replaced if the wear limit is exceeded!

The maximum permissible wear at the specified measurement point is 100 $$m (= 0.1 mm). The piston must be replaced if this dimension is exceeded! The reference dimensions for the piston groups are to be taken from the following table.

Note. Original pistons from the Porsche spare parts catalogue are available in the dimension group X only. Note the different weight groups!

DIMENSION SPECIFICATION - PISTONS

Scheme 771

SPECIAL TOOLS (1 OF 2)

Scheme 772

SPECIAL TOOLS (1 OF 2)

REMOVING CYLINDER HEAD COVER - CYLINDER BANKS 1 - 3 AND 4 - 6

1. Preliminary work: drain engine oil.

Scheme 773

Scheme 774

1. Pull off the cable plug on the oil pressure sensor.
2. Remove 3 ignition coils. Pull off the cable plug on the ignition coils. Unscrew 2 M6 x 25 pan-head screws (hexagon socket a/f 5), pull the ignition coils out of the spark-plug recess. NOTE: If the camshaft adjustment valve is to be removed, the O-ring and the oil strainer must be replaced. The cover with integral seal for the camshaft adjustment valve must be replaced.
3. Pull off the cable plug on the camshaft adjustment valve. Remove the holder and the cover for the valve on the cylinder head cover. Unscrew the two M6 x 20 pan-head screws (hexagon socket a/f 5), remove the connection cable for the camshaft adjustment valve from the sheetmetal bracket and remove the holders. Pull off the valve cover. CAUTION: When levering off the cylinder head cover, the cast lugs may break.
4. Remove cylinder head cover. Unscrew 20 M6 x 30 hexagon-head bolts from the cylinder head cover and the 2 M6 x 20 hexagon-head bolts, which are screwed to the cylinder head cover, from the oil extraction pump. To release the cylinder head cover, raise the cover carefully at the two protruding cast edges with a slotted screwdriver. Remove cylinder head cover. NOTE: Once you have levered off the cylinder head cover, check the O-ring on the oil extraction pump for damage (particularly in the disconnection point area). If the O-ring needs to be replaced, also unscrew the 2 lower M6 x 20 hexagon-head bolts and remove the pump.
5. Remove the brown closure cap (45 mm) and 2 green closure caps.

CYLINDER BANK 4- 6

1. Remove 3 ignition coils. Pull off the cable plug on the ignition coils. Unscrew the two M6 x 25 pan-head screws (hexagon socket a/f 5), pull the ignition coils out of the spark-plug recess. NOTE: If the camshaft adjustment valve is to be removed, the O-ring and the oil strainer must be replaced. The cover with integral seal for the camshaft adjustment valve must be replaced.
2. Pull off the cable plug on the camshaft adjustment valve. Remove the holder and the cover for the valve on the cylinder head cover. Unscrew the two M6 x 20 pan-head screws (hexagon socket a/f 5), remove the connection cable for the camshaft adjustment valve from the sheetmetal bracket and remove the holders. Pull off the valve cover.
3. Remove cylinder head cover. Repeat step 4 as with cylinder bank 1-3. NOTE: Once you have levered off the cylinder head cover, check the O-ring on the oil extraction pump for damage (particularly in the disconnection point area). If the O-ring needs to be replaced, also unscrew the 2 lower M6 x 20 hexagon-head bolts and remove the pump.
4. Remove the brown closure cap (45 mm) and 2 green closure caps.

INSTALLING CYLINDER HEAD COVER - CYLINDER BANKS 1-3 AND 4-6

Note. The sealing surfaces of the cylinder heads and the cylinder head covers must be cleaned before the new sealant is applied. Avoid damage!

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

1. Clean sealing surfaces. Remove any sealant residue from the sealing surfaces on the cylinder head and the cylinder head cover thoroughly. Then rub down with a clean cloth soaked in a decreasing agent (e.g. acetone, solvent naphtha). Make sure that no sealant residue can enter the cylinder head. NOTE: Replace the seals for the spark-plug recesses.
2. Insert the 3 seals for the spark-plug recesses. NOTE: Only if the camshaft adjustment valve was removed: Replace oil strainer -arrow-. (Scheme 782) Insert camshaft adjustment valve with a new O-ring again (installation position: ensure that dowel pin is in the cylinder head bore). Only the following sealants may be used to seal the cylinder head cover (these are available from the Porsche Parts Service): "Drei Bond" silicone - type 1209 Loctite 5900
3. Fix cylinder head cover. Apply a thin bead of sealant on the cylinder head cover. see scheme 563 The bead should not be higher than 1.5 mm. NOTE: If the O-ring of the oil extraction pump needs to be replaced, insert the pump after fastening the cylinder head cover and then position the 4 M6 x 20 hexagon-head bolts. Identification on the oil extraction pump in see scheme 564 cylinder side 1-3 faces the crankcase.
4. Fit 20 M6 x 30 hexagon-head bolts on the cylinder head cover and 2 or 4, M6 x 20 hexagon-head bolts for the oil extraction pump. see scheme 565
5. Tighten the 20 hexagon-head bolts in the specified tightening sequence to the specified torque. Tightening torque 13 Nm (9.5 ft.lb)
6. Tighten 2 or 4 M6 x 20 hexagon-head bolts of the oil extraction pump to the specified torque. Tightening torque 13 Nm (9.5 ft.lb) NOTE: Replace all plastic closure caps on the cylinder head/cylinder head cover joint.
7. For each cylinder head, place a new, brown, dry closure cap (45 mm) on the bore for the exhaust camshaft and tap it in gently with a plastic hammer.
8. Insert 2 new, green, dry closure caps for each cylinder head into the small bores and tap them in gently with a plastic hammer. NOTE: Replace cover with integral seal for the camshaft adjustment valve.
9. Slide the new cover over the camshaft adjustment valve, place holder with 2 M6 x 20 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to valve. Tightening torque 10 Nm (7.5 ft.lb)
10. Fit ignition coils. Insert 3 ignition coils into the spark-plug recesses for each cylinder bank. Unscrew 2 M6 x 25 pan-head screws for each ignition coil hexagon socket a/f 5) on the cylinder head cover and tighten to the specified torque. Connect cable plug to ignition coils. Tightening torque 10 Nm (7.5 ft.lb.)
11. Cylinder bank 1 - 3: Connect cable plug to oil pressure sensor.

TIGHTENING TORQUES - CYLINDER HEAD COVER, AS OF MY 2003

REMOVING AND INSTALLING VALVE STEM SEAL

Insert VW special tool 3364 into rib of valve stem seal and pull out.

Scheme 780

Fit original valve spring support disc. Slide plastic assembly sleeve ($$ 6 mm) onto valve stem. Oil sealing lip and seating surface of valve stem seal, put on by hand and, with assembly mandrel (VW special tool 3365), gently tap as far as the stop on the valve guide. Remove plastic sleeve.

Scheme 781

Scheme 782

REMOVING AND INSTALLING CAMSHAFTS - UP TO MODEL YEAR 2002

REMOVAL AND INSTALLATION PROCEDURE FOR CAMSHAFTS (UP TO MODEL YEAR 2002)

Note. Magnetized tools or magnets must not be used when removing and installing valve tappets (flat-base tappets). A suitable removal tool is a rubber suction cup, for example.

CAMSHAFTS OF CYLINDER BANK 1 - 3

Identification on the camshaft

Inlet camshaft: 221,04/2,5 IN 13

Exhaust camshaft: 222,04/2,5 EX 13

CAMSHAFTS OF CYLINDER BANK 4-6

Identification on the camshaft

Inlet camshaft: 216,04/2,5 IN 46

Exhaust camshaft: 218,04/2,5 EX 46

Scheme 783

Allocating chain tensioners

Identification of the chain tensioner for cylinder bank 1 - 3

Scheme 784

1. Cylinder bank 1 - 3
2. Solenoid valve surface color black

Identification of the chain tensioner for cylinder bank 4 - 6

Scheme 785

1. Cylinder bank 4 - 6
2. Solenoid valve surface color grey

REMOVING AND INSTALLING CAMSHAFTS - AS OF MY 2003

Scheme 786

SPECIAL TOOLS

PRELIMINARY WORK

1. Engine removed
2. Engine oil drained
3. Air conditioning compressor removed
4. Servo-tank removed
5. Exhaust system removed (without manifold)

1. Designation on the camshafts 1 - 3

Scheme 787

1. A: Exhaust camshaft: 222.10/2.7 EX 1 - 3
2. B: Inlet camshaft: 221.10/2.7 IN 1 - 3

1. Designation on the camshafts 4 - 6

Scheme 788

1. A: Exhaust camshaft: 218.10/2.7 EX 4 - 6
2. B: Inlet camshaft: 216.10/2.7 IN 4 - 6

1. Designation on the camshafts 1 - 3

Scheme 789

1. A: Exhaust camshaft: 222.61/3.2 EX 1 - 3
2. B: Inlet camshaft: 221.61/3.2 IN 1 - 3

1. Designation on the camshafts 4 - 6

Scheme 790

1. A: Exhaust camshaft: 218.61/3.2 EX 4 - 6
2. B: Inlet camshaft: 216.61/3.2 IN 4 - 6

PRESUMABLE CAMSHAFTS

The inlet camshaft, exhaust camshaft, tensioning element (VarioCam) and chain must be preassembled before installation in the cylinder head.

Identification on the camshaft

CAMSHAFT IDENTIFICATION CODE (CYLINDER BANK 1 - 3)

Identification on the camshaft

CAMSHAFT IDENTIFICATION CODE (CYLINDER BANK 4 - 6)

Scheme 791

Scheme 792

1. Cyl. 1-3
2. Solenoid valve surface color black

Scheme 793

1. Cylinder bank 4
2. Solenoid valve surface color grey

Move camshafts, chain and tensioning element of cylinder bank 1 - 3 basic position or installation position.

Scheme 794

Scheme 795

Scheme 796

Scheme 797

Scheme 798

Scheme 799

1. Place the inlet camshaft and exhaust camshaft on a soft surface. The lug of the camshaft position sensor cover or the groove on the inlet camshaft and the dotting marks must face upward.
2. Place chain on the drive sprockets of the camshafts. The colored outer lugs of the chain must face the dotting marks.
3. Fit tensioning element. Press slide rails together and push upward. Lift inlet camshaft and insert tensioning element from the front. Fit chain; when doing so, observe clearance between the gear wheels and the lower slide rail.
4. Completely preassembled and ready for installation. Do not remove the tensioning screw, special tool 9632, until the bearing saddles and the chain tensioner have been fastened on the cylinder head. If allocation is correct, the groove or lug of the camshaft position sensor housing face upward.

Scheme 800

Move camshafts, chain and tensioning element of cylinder bank 4 -152,40 mm basic position or installation position.

Scheme 801

Scheme 802

Scheme 803

Scheme 804

Scheme 805

1. The lug of the camshaft position sensor cover or the groove on the inlet camshaft must face downward. The dotting marks must face upward. NOTE: The rotor cover for the camshaft position sensor is no longer installed in vehicles without M660 (OBDII) or M661 (more demanding emission concept).
2. Put on and fit chain as described for cylinder bank 1 - 3.
3. Completely assembled and ready for installation. Do not remove the tensioning screw, special tool 9632, until the bearing saddles and the chain tensioner have been fastened on the cylinder head. If allocation is correct, the groove or lug of the camshaft position sensor housing faces downward. NOTE: Modified tensioning element (VarioCam) as of June 1999. The tensioning screw has been changed to a LEFT-HAND THREAD. Can be identified by the index (57) in the area of the guide rails Introduction as of engine number 65X19696

SEALING COVER FOR CAMSHAFT HOUSING (CYLINDER HEAD COVER)

Sealing the sealing surface of the cylinder head cover

Use only the sealants Drei Bond silicone - type 1209 and Loctite 5900 to seal the sealing surface on the cylinder head cover.

Note. After the sealant has been applied, the cylinder head must be joined with the cylinder head cover within 5 minutes.

Application of silicone bead

At the processing nozzle, cut off the first metering step.

Apply a uniform bead approximately 1.5 mm wide to the cleaned sealing surface of the cylinder head cover.

Scheme 806

Applying the sealant on the sealing surface of the cylinder head cover

Scheme 807

Apply bead of sealant in the bearing saddle area

Scheme 808

Seal screw union at the oil pressure duct.

If the hexagon-head bolt (arrow) was loosened, the micro-encapsulated hexagon-head bolt must always be replaced.

Part number 900.378.163.09 (M6 x 16)

Scheme 809

CHECKING GUIDE FOR VALVE TAPPETS

Before installing the valve tappet guide in the cylinder head, check it for damage or existing defects. The valve tappet guide must be replaced if it displays irregularities deviating from the limit sample photo.

The irregularities shown in the limit sample photo are normal and must not be classified as damage influencing the function of the part or requiring replacement of the part.

Scheme 810

SPECIAL TOOLS

INSTALLING CLOSURE CAPS AT PULLEY SIDE OF CYLINDER HEAD 4 - 6

1. Clean receiving bore. Fit new cap dry and press in as far as it will go.
2. Install rear wall lining and rear wall cover.

Tightening torque 10 Nm (7.5 ft.lb)

Scheme 811

Scheme 812

Scheme 813

1. Remove rear wheels. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.
2. Detach cable between engine and rear-axle carrier at the rear-axle support. When loosening, hold with a second wrench (a/f 13).
3. Unscrew four fastening screws on both sides of the rear-axle support (a/f 15).
4. A shop-made tool is required in order to pull off the cap. Making the tool: Weld a 6.3 x 14 sheetmetal screw with hexagon head onto a 1000 mm long iron rod, for example, 8 mm round steel bar. (Scheme 821)
5. Shift the loosened rear-axle support accordingly until the closure cap becomes accessible.
6. Turn puller into Centre of the closure cap and pull off the cap -arrow-. (Scheme 822)

Scheme 814

INSTALLING CLOSURE CAPS AT FLYWHEEL SIDE OF CYLINDER HEAD 1 - 3

1. Clean receiving bore. Fit new cap dry and press in as far as it will go.
2. Fit rear-axle supports. Tightening torque 65 Nm (48 ft.lb)
3. Fasten cable. Tightening torque: 23 Nm (17 ft.lb)
4. Mount rear wheels. To do this, use the socket wrench insert P 300 to avoid damaging the wheel. Tightening torque 130 Nm (96 ft.lb).
5. Measure vehicle axle.

Scheme 815

Scheme 816

Scheme 817

1. Remove rear wheels. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.
2. Detach cable between engine and rear-axle carrier at the rear-axle support. When loosening, hold with a second wrench (a/f 13).
3. Unscrew four fastening screws on both sides of the rear-axle support (a/f 15).
4. A shop-made tool is required in order to pull off the cap. Making the tool: Weld a 6.3 x 14 sheetmetal screw with hexagon head onto a 1000 mm long iron rod, e.g. 8 mm round steel bar. (Scheme 825)
5. Shift the loosened rear-axle support accordingly until the closure cap becomes accessible.
6. Turn puller into Centre of the closure cap and pull off the cap.

Scheme 818

1. Clean receiving bore. Fit new cap dry and press in as far as it will go.
2. Fit rear-axle supports. Tightening torque 65 Nm (48 ft.lb).
3. Fasten cable. Tightening torque 23 Nm (17 ft.lb)
4. Mount rear wheels. To do this, use the socket wrench insert P 300 to avoid damaging the wheel. Tightening torque 130 Nm (96 ft.lb).
5. Measure vehicle axle.

TIGHTENING TORQUE SPECIFICATIONS - CLOSURE CAP FOR CAMSHAFT BORE

Scheme 819

SPECIAL TOOLS

REMOVING SEALING RING FOR INTERMEDIATE SHAFT

1. Remove manual transmission. Refer to «REMOVING AND INSTALLING TRANSMISSION G 86»(ref-199504-S01212861952005101900000) .
2. Remove Tiptronic transmission. Refer to «REMOVING AND INSTALLING TIPTRONIC TRANSMISSION»(ref-199506-S31068014792005101900000) .

Note. In order to avoid deforming the thrust plate housing, always loosen the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.

Scheme 820

Scheme 821

Scheme 822

Scheme 823

Scheme 824

Scheme 825

1. Remove the clutch pressure plate, including the drive plate. Refer to «DISASSEMBLING AND ASSEMBLING CLUTCH»(ref-199502-S09692030992005101900000).
2. Remove drive plate for the torque converter or the double-mass flywheel (DMF). Fasten special tool toothed segment 9538/1 for countering on the right crankcase half (cylinder bank 1 - 3) with an M10 x 50 screw. Undo and remove drive plate or DMF.
3. Drain engine oil. After a dripping time of 20 minutes, insert oil drain plug with new sealing ring and tighten. Tightening torque 50 Nm (37 ft.lb)
4. Turn the engine on the crankshaft belt pulley clockwise until the bore 1 TDC (top dead Centre) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with special tool fixing pins 9595/1. (Scheme 829) Use short fixing pin.
5. Remove camshaft closure caps from cylinder bank 1 - 3. The closure cap of cylinder bank 1 - 3 is located on the flywheel side. Drive small screwdriver into Centre of the closure cap and lever off the cap.
6. Check basic camshaft adjustment -arrow-. see scheme 772 If the position is not correct, remove the dowel pin and turn the crankshaft a further 360° in clockwise direction. Fix belt pulley again with fixing pin.
7. Turn primary chain tensioner out of the crankcase, cylinder bank 4 - 6.
8. Turn secondary chain tensioner out of the cylinder head 1 - 3.
9. Undo intermediate shaft flange. Unscrew the three fastening screws M6 x 20 on the intermediate-shaft flange. Undo the M8 x 1 lock nut with the socket wrench 9110. (Scheme 830) At the same time, counter with a suitable screwdriver in the slotted threaded pin.
10. Position and align special tool retaining device 9642. (Scheme 831) Tensioning the retaining device
11. Carefully press the intermediate shaft off, for instance with two angle screwdrivers. (Scheme 833) Proceed carefully so as not to damage the sealing surfaces.

Scheme 826

Scheme 827

Scheme 828

Scheme 829

1. Check crankcase bore for sharp edges. Break off (deburr) any sharp edges on the crankcase bore (intermediate shaft flange) with polishing cloth or an oilstone.
2. Grease the new sealing ring slightly with Optimoly MP3 (available from Porsche Parts Service) and insert in the groove of the intermediate shaft flange. NOTE: The sealing ring must not be twisted and must not be pulled over sharp edges of the flange.
3. Position intermediate shaft flange on the bore and affix with new micro-encapsulated hexagon-head bolts. NOTE: Do not exert any pressure on the threaded pin when pushing in the intermediate shaft flange, as the threaded pin might otherwise be pressed inward into the intermediate shaft. As soon as the threaded pin projects at the intermediate shaft flange, screw the new lock nut into position.
4. Position and align special tool retaining device 9642. (Scheme 834) Centre intermediate shaft and intermediate shaft flange by turning the crankshaft to and fro a little (max. 2° to 3°, remove dowel pin from the belt pulley first). NOTE: It must be possible to insert the intermediate shaft flange almost completely into the intermediate shaft bore by hand.
5. Tighten the three micro-encapsulated M6 x 20 hexagon-head bolts evenly. (Scheme 835) Tightening torque 10 Nm (7.5 ft.lb)
6. Tighten lock nut M8 x 1 with the socket wrench 9110. At the same time, have a second person counter with a suitable screwdriver in the slotted threaded pin. (Scheme 836) Tightening torque 11 Nm (8 ft.lb)
7. Fit new sealing rings to both chain tensioners, screw in and tighten. Tightening torque 80 Nm (59 ft.lb)
8. Fill in engine oil. Refer to «ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE»(ref-199492-S03555411242005101900000) or «CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003»(ref-199492-S07492014942005101900000).. NOTE: Replace screws for the double-mass flywheel and drive plate for the torque converter.
9. Fit double-mass flywheel or drive plate for the torque converter. NOTE: In order to avoid deforming the thrust plate housing, always tighten the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
10. Fit the clutch pressure plate with drive plate.
11. Install manual transmission or Tiptronic transmission.

TIGHTENING TORQUES - SEALING RING FOR INTERMEDIATE SHAFT

REWORKING CYLINDER HEAD

1. Carefully clean the removed cylinder head (parts washing machine, solvent naphtha). Remove residual sealant from the sealing surface, e.g. with (commercially available) foil eraser or acetone.
2. Check sealing surface of cylinder head for distortion using a straight-edge. Permissible unevenness of the parting plane: 0.05 mm
3. Cylinder heads with distorted sealing surface can be repaired by surface milling. NOTE: The permissible peak-to-valley surface roughness for machining the sealing surface is 0.015 mm. Rework sealing surface of the cylinder head only until a flat surface has been achieved.

Permissible unevenness of parting plane: 0.03 mm

The permissible wear -X- for the cylinder head height is be taken from the following table.

Scheme 830

CYLINDER HEAD HEIGHT SPECIFICATIONS

CAMSHAFT ASSIGNMENT

Engine type M96/20 (2.5L)

Engine type M96/22 (2.7L)

Engine type M96/21 (3.2L)

Note. The code is engraved into the camshaft.

Scheme 831

Boxster camshafts (2.5L)

Engine type M96/20

Camshafts of cylinder bank 1 - 3

Identification on the camshaft

Inlet camshaft: 221.04/2.5 IN 1 - 3

Exhaust camshaft 222.04/2.5 EX 1 - 3

Camshafts of cylinder bank 4 - 6

Identification on the camshaft

Inlet camshaft 216.04/2.5 IN 4 - 6

Exhaust camshaft: 218.04/2.5 EX 4 - 6

Boxster camshafts (2.7L)

Engine type M96/22

Camshafts of cylinder bank 1 - 3

Identification on the camshaft

Inlet camshaft: 221.05/2.7 IN 1 - 3

Exhaust camshaft: 222.05/2.7 EX 4 - 6

Camshafts of cylinder bank 4 - 6

Identification on the camshaft

Inlet camshaft 216.05/2.7 IN 4 - 6

Exhaust camshaft: 218.05/2.7 EX 4 - 6

Boxster S camshafts (3.2L)

Engine type M96/21

Camshafts of cylinder bank 1 - 3

Identification on the camshaft

Inlet camshaft 221.55/3.2/3.4 IN 1 - 3

Exhaust camshaft: 222.55/3.2/3.4 EX 1 - 3

Camshafts of cylinder bank 4 - 6

Identification on the camshaft

Inlet camsh 216.55/3.2/3.4 IN 4 - 6

Exhaust camshaft: 218.55/3.2/3.4 EX 4 - 6

REMOVING THE HYDRAULIC VALVE

Scheme 832

Scheme 833

Scheme 834

1. Remove respective rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.
2. Remove cable plug of the hydraulic valve -1- by pressing the clip and pulling off the cable plug. see scheme 783
3. Unscrew the two M6 pan-head screws (hexagon socket a/f 5) of the valve holder see scheme 783 and remove the holder with the screws -A-. see scheme 784
4. Remove retainer plate with integral seal from the valve. see scheme 783
5. Carefully pull the hydraulic valve out of the cylinder head using special tool (relay puller) 9235. Mask the valve sheath with fabric tape to avoid damage.

INSTALLING THE HYDRAULIC VALVE

Note. Always replace O-ring of the hydraulic valve and the retainer plate! Observe installation position of the hydraulic valve! Replace oil strainer -arrow-. see scheme 786

Scheme 835

Scheme 836

Scheme 837

1. Replace the O-ring of the hydraulic valve and coat the new O-ring with engine oil. Insert hydraulic valve into the cylinder head, paying attention to the installation position (groove on valve -arrow- faces the dowel pin in the cylinder head). see scheme 787 Remove fabric tape.
2. Coat seal of the retainer plate with engine oil and slide it over the hydraulic valve.
3. Fit both M6 pan-head screws (hexagon socket a/f 5) complete with holder on the valve and tighten the screws. Tightening torque 10 Nm (7.5 ft.lb)
4. Push the cable plug onto the hydraulic valve again. Make sure that the plug audibly engages. Clip cabling to sheetmetal bracket.
5. Remove rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.

Tightening torque 130 Nm (96 ft.lb).

INSTALLING CYLINDER HEAD COVER - CYLINDER BANKS 1 - 3 AND 4 - 6 - USA vehicles

Note. The sealing surfaces of the cylinder heads as well as the cylinder head covers must be cleaned carefully before the new sealant is applied. Avoid damage!

Scheme 838

Scheme 839

Scheme 840

Scheme 841

Scheme 842

Scheme 843

Scheme 844

Scheme 845

Scheme 846

Scheme 847

Scheme 848

1. Clean sealing surfaces. Remove any sealant residue from the sealing surfaces on the cylinder head and the cylinder head cover thoroughly. Then rub down with a clean cloth soaked in a decreasing agent (e.g. acetone, solvent naphtha). Make sure that no sealant residue can enter the cylinder head. NOTE: Replace the seals for the spark-plug recesses.
2. Insert the 3 seals for the spark-plug recesses. NOTE: Only if the camshaft adjustment valve was removed: Pull the oil strainer -arrow- out using pointed-nose pliers and replace! (Scheme 847) Only the following sealants may be used to seal the cylinder head cover (these are available from the Porsche Parts Service): "Drei Bond" silicone - type 1209 Loctite 5900 NOTE: When applying the sealant, always make sure that the oil ducts in the cylinder head are not blocked!
3. Carefully apply a thin bead of sealant on the cylinder head cover. (Scheme 848) The bead should not be higher than 1.5 mm.
4. Push the coolant lines aside and fix cylinder head cover. Fasten coolant lines.
5. Position 20 M6 x 30 hexagon-head bolts on the cylinder head cover.
6. Tighten the 20 hexagon-head bolts in the specified tightening sequence to the specified torque. Tightening torque 13 Nm (9.5 ft.lb) NOTE: If the O-ring of the oil extraction pump needs to be replaced, insert the pump after fastening the cylinder head cover and then position the 4 M6 x 20 hexagon-head bolts. Identification on the oil extraction pump in the Figure cylinder side 1 - 3 faces the crankcase. (Scheme 850) The screws for the oil extraction pump are micro-encapsulated and are therefore to be replaced.
7. Carefully remove excess sealant before installing the oil extraction pump. Insert oil extraction pump in the fitting bore.
8. Position 4 M6 x 20 hexagon-head bolts (micro-encapsulated) on the oil extraction pump and tighten to the specified torque. Tightening torque 13 Nm (9.5 ft.lb) NOTE: Replace all plastic closure caps on the cylinder head/cylinder head cover joint.
9. For each cylinder head, place a new, brown, dry closure cap (45 mm) on the bore for the exhaust camshaft and press in until they are flush.
10. Insert 2 new, green, dry closure caps for each cylinder head into the small bores and press in until they are flush.
11. Insert camshaft adjustment valve with a new O-ring again (installation position: ensure that dowel pin is in the cylinder head bore!). NOTE: Replace cover with integral seal for the camshaft adjustment valve!
12. Slide the new cover over the camshaft adjustment valve, place holder with 2 M6 x 20 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Push cable plug onto camshaft adjustment valve. Tightening torque 10 Nm (7.5 ft.lb)
13. Fit ignition coils. Insert 3 ignition coils into the spark-plug recesses for each cylinder bank. Position 2 M6 x 25 pan-head screws for each ignition coil hexagon socket a/f 5) on the cylinder head cover and tighten to the specified torque. Connect cable plug to ignition coils. Tightening torque 10 Nm (7.5 ft.lb)
14. Cylinder bank 1 - 3: Connect cable plug to oil pressure sensor.
15. Cylinder bank 1 - 3: Fit side plastic cover by screwing two M6 hexagon-head bolts -arrows- into place. (Scheme 851) Tightening torque 10 Nm (7.5 ft.lb)
16. Cylinder bank 4 - 6: Attach the holder for the servo line by tightening the M6 hexagon-head bolt -arrow-. (Scheme 852) Tightening torque 10 Nm (7.5 ft.lb.) NOTE: Always replace the metal seals on the exhaust manifold and flange. The M8 x 28 exhaust manifold screws are to be replaced. Replace the screws and nuts on the flange if necessary.
17. Install exhaust manifold with catalytic converter. To do this, screw the exhaust manifold into place on the catalytic converter using 2 M8 hexagon nuts and one M8 hexagon-head bolt and on the cylinder head using 6 new M8 x 28 hexagon-head bolts. Replace metal seals. Tightening torque 23 Nm (17 ft.lb.)
18. Attach oxygen sensor cable plug holder to cylinder head cover by tightening the M6 hexagon-head bolt. Lay oxygen sensor cable and clip in to sheetmetal bracket. Connect both oxygen sensor cable plugs in front of and behind the catalytic converter. Side oxygen sensor cable plug in front of catalytic converter Tightening torque screw for holder 10 Nm (7.5 ft.lb) Side oxygen sensor cable plug behind catalytic converter
19. Attach side plastic strut by tightening the M6 hexagon nut -arrow-. (Scheme 855) Tightening torque 10 Nm (7.5 ft.lb)
20. Fit the rear underbody panel. Position the torx screws, plastic nuts and the Centre M6 hexagon nut and tighten.
21. Mount respective rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel. Tightening torque 130 Nm (96 ft.lb).
22. Fill engine oil according to specifications. Refer to «ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE»(ref-199492-S03555411242005101900000) or «CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003»(ref-199492-S07492014942005101900000).
23. Connect the battery. Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199496-S08906116372005101900000).

The process of removing and installing cylinder head covers for RoW vehicles is similar to that for USA vehicles with the following exception

1. The exhaust manifolds need not be removed.

Note. Note the work instructions for disconnecting and reconnecting the battery. Move convertible top to service position, see REMOVING AND INSTALLING CONVERTIBLE TOP . Remove the engine compartment lid and the maintenance cover in the passenger compartment. Refer to ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT . Disconnect the battery, see WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY . Remove Tiptronic transmission. Refer to REMOVING AND INSTALLING TIPTRONIC TRANSMISSION and REMOVING AND INSTALLING TRANSMISSION G 86 . Drain engine oil (insert the oil drain plug again with a new aluminum sealing ring and tighten with a tightening torque of 50 Nm (37 ft.lb).

REMOVING BEARING COVER

Note. The air conditioning circuit must not be opened to release the air conditioning compressor!

Scheme 849

Scheme 850

Scheme 851

Scheme 852

1. Lever out 2 green closure caps on the cylinder bank 1 - 3 pulley side. See «REMOVING AND INSTALLING CLOSURE CAP FOR CAMSHAFT BORE - ENGINE INSTALLED»(ref-199829-S28270013372005102100000) .
2. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to overlapping TDC of cylinder bank 1 - 3 and fix it with special tool fixing pins 9595/1 (use short fixing pin). NOTE: For checking with the adjusting gauge, the timing adjustment must be correct.
3. In order to check the camshaft adjustment of special tool, insert adjusting gauge 9686 for camshaft into the camshaft slots (pulley side) (Inscription on gauge points towards the cylinder head cover), see also «INSTALLING CAMSHAFT - ENGINE REMOVED - INCLUDES ADJUSTING TIMING, - AS OF MY 2003»(ref-199829-S37451577612005102100000) . If the gauge can't be inserted, rotate the crankshaft a further 360°. NOTE: After removal of the chain tensioner, the crankshaft must not be turned under any circumstances, because otherwise the timing chain may jump over! Drill open the bore of the toothed segment to 15 mm to counter against the toothed ring.
4. Remove the torque-converter drive plate. Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw. Unscrew 8 M10 x 25 x 1 Torx socket screws and remove drive plate. NOTE: In order to avoid deforming the thrust plate housing, always loosen the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
5. Remove thrust plate and drive plate. Release and unscrew 6 M8 pan-head screws gradually and in diametrically opposite sequence.
6. Remove double-mass flywheel (DMF). Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw. Unscrew 8 M10 x 50 Torx socket screws and remove the DMF.
7. Unscrew 2 M6 x 12 hexagon-head bolts on the coolant pipe (heating) cylinder side 4 - 6.
8. Remove primary chain tensioner and chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32). -A- Primary chain tensioner ; -B- chain tensioner, cylinder bank 1 - 3 NOTE: In order to make it easier to remove the bearing cover, the sealing surface can be sprayed with anti-rust agent.
9. Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket wrench 9110, at the same time countering at the slotted threaded pin on the intermediate shaft with a suitable screwdriver.
10. Unscrew the three M6 x 20 hexagon-head bolts (micro-encapsulated) on the intermediate-shaft flange. Replace screws during installation. NOTE: Lever the bearing cover out carefully so as not to damage the sealing surfaces. Turning several times to the left and right loosens the bearing cover. After removing the bearing cover, do not press the threaded bolts of the intermediate shaft.
11. Lever the bearing cover out carefully using, for instance, two screwdrivers (or angle screwdrivers). Move the bearing cover frequently to the left and right to make levering out easier. Do not damage the sealing surfaces.

INSTALLING BEARING COVER

Note. Replace bearing cover!

Scheme 853

Scheme 854

Scheme 855

Scheme 856

Scheme 857

1. Before installing the new bearing cover, check the fitted bore on the crankcase for sharp edges and burrs. They should be removed with an oilstone or a polishing cloth. Remove any existing residue and clean the bore with a clean cloth soaked in solvent naphtha or acetone. NOTE: Replace hexagon collar nut M8 x 1 and micro-encapsulated screws for bearing cover!
2. Grease fitted bore and new bearing cover with special grease Optimoly MP3 (available from Porsche Parts Service) and place bearing cover in position.
3. Position 3 new M6 x 20 hexagon-head bolts (micro-encapsulated) on the crankcase and pull in the bearing cover by screwing in the screws uniformly. Tighten screws to the specified torque. Tightening torque 10 Nm (7.5 ft.lb)
4. Position new M8 x 1 hexagon nut on the threaded pin of the intermediate shaft. Tighten the nut with special tool socket wrench 9110 to the correct tightening torque. At the same time, counter with a suitable screwdriver in the slotted threaded pin of the intermediate shaft. Tightening torque 12 + 1 Nm (9 + 0.5 ft.lb).
5. Install both primary chain tensioner and chain tensioner cylinder bank 1 - 3 with a new aluminum sealing ring (hexagon a/f 32) and tighten to the correct tightening torque. -A- Primary chain tensioner ; -B- chain tensioner, cylinder bank 1 - 3 Tightening torque 80 Nm (59 ft.lb)
6. Fasten coolant pipe (heating), cylinder side 4 - 6, with 2 M6 x 12 hexagon-head bolts. Tightening torque 10 Nm (7.5 ft.lb)
7. Pull fixing pin out of the fixing bore. NOTE: Fastening screws for drive plate for the torque converter or the double-mass flywheel must be replaced! Drill open the bore of the toothed segment to 15 mm to counter against the toothed ring.
8. Install double-mass flywheel or drive plate for torque converter with new screws. Fit special tool toothed segment 9538/1 for countering using an M12 x 50 screw. Tightening torque 25 Nm (19 ft.lb) + 120° torque angle NOTE: In order to avoid deforming the thrust plate housing, always tighten the pan-head screws on the clutch pressure plate in several stages and in diametrically opposite sequence.
9. Manual transmission: Install thrust plate and drive plate. Tighten 6 M8 pan-head screws to the prescribed torque. Tightening torque: 23 Nm (17 ft.lb.)
10. Install Tiptronic transmission. Refer to «REMOVING AND INSTALLING TIPTRONIC TRANSMISSION»(ref-199506-S31068014792005101900000) and «REMOVING AND INSTALLING TRANSMISSION G 86»(ref-199504-S01212861952005101900000) .
11. Fill engine oil. Refer to «ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE»(ref-199492-S03555411242005101900000) or «CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003»(ref-199492-S07492014942005101900000)
12. Install the engine compartment lid and the maintenance cover in the passenger compartment. Refer to «ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT»(ref-199492-S29076881312005101900000) .
13. Connect the battery. Refer to «WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY»(ref-199496-S08906116372005101900000) .
14. Close convertible top, see «REMOVING AND INSTALLING CONVERTIBLE TOP»(ref-199808-S02308229562005102000000) (Model year 2003).

WEAR OF TIMING CHAINS, SPROCKETS, TENSIONING AND SLIDE RAILS

Note. Pay strict attention to cleanliness during removal and fitting! Lay removed engine parts on a clean base and cover them. Coat new parts with new engine oil before installation.

1. For the chain, drive no wear values (such as chain elongation) are specified. Before disassembly, the engine should therefore be run and checked for noises in the chain drive area. If there are noises in the chain drive area, replacement of the individual parts is recommended!
2. During disassembly, carefully check the spare parts (sprockets, timing chains, tensioning and slide rails) for signs of wear, e.g. abrasion of the sprockets, signs of rubbing on the tensioning and slide rails.

Note. If in doubt replace the parts!

Visible symptoms of wear are still permissible, but if the wear is appreciable then the affected parts must be replaced!

Engine type M 96/23 and M 96/24

Note. The timing should always be checked simultaneously on both cylinder banks. The check is performed with the standard chain tensioners installed.

Scheme 858

Scheme 859

Scheme 860

Scheme 861

Scheme 862

Scheme 863

Scheme 864

Scheme 865

Scheme 866

1. Unscrew the four plastic nuts of the carpeted rear wall and pull the rear wall upwards out of the vehicle. Open the maintenance cover behind the seats. To do so, unscrew the 7 fastening screws and the 2 fastening nuts and remove the maintenance cover. Refer to «ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT»(ref-199492-S29076881312005101900000).
2. Turn the engine clockwise at the pulley of the crankshaft to the TDC marking of cylinder 1. Fix with special tool (fixing pins) 9595/1 (short fixing pin).
3. Drain engine oil. Then equip the drain plug with a new sealing ring, screw it in and tighten it to the specified tightening torque. Tightening torque of the M18 hexagon socket head screw: 50 Nm (37 ft.lb)
4. Remove the rear underbody panel. Undo the torx screws, plastic nuts and the Centre M6 hexagon nut.
5. Remove side plastic strut by undoing the M6 hexagon nut -arrow-. (Scheme 870)
6. Remove all four green caps on the camshaft housing covers on both cylinder heads. See «REMOVING AND INSTALLING CLOSURE CAP FOR CAMSHAFT BORE - ENGINE INSTALLED»(ref-199829-S28270013372005102100000). Press a small screwdriver into the Centre of the piercing point of the each cap and lever out the cap.
7. Check the cylinder side that is at overlapping TDC first (the smaller circular cutout on the milled groves of the inlet and exhaust camshafts points faces the cylinder head cover) -arrows- using setting gauge 9686. Then turn the engine 360° further and check the other cylinder side as well. (Scheme 872) Position of the camshafts in overlapping TDC of cylinder 1 or 4 (the smaller circular cutout on the milled grooves of the inlet and exhaust camshafts faces the cylinder head cover)
8. Remove setting gauge 9686 and fit two new green caps on each of the camshaft housing covers.
9. Fit side plastic strut with the M6 hexagon nut -arrow-. (Scheme 874) Tightening torque 10 Nm (7.5 ft.lb)
10. Fit the rear underbody panel. Position the torx screws, plastic nuts and the Centre M6 hexagon nut and tighten.
11. Remove special tool fixing pins 9595/1 on the pulley of the crankshaft.
12. Fit the maintenance cover behind the seats. To do so, screw in and tighten the 7 fastening screws and the 2 fastening nuts. Refer to «ENGINE MAINTENANCE: OPENING AND CLOSING ENGINE COMPARTMENT»(ref-199492-S29076881312005101900000). Tightening torque 10 Nm (7.5 ft.lb)
13. Fit carpeted rear wall. To do this, tighten the four plastic nuts.
14. Fill in engine oil. Refer to «ENGINE MAINTENANCE: OIL CHANGE WITH FILTER CHANGE»(ref-199492-S03555411242005101900000) or «CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003»(ref-199492-S07492014942005101900000).

REMOVING AND INSTALLING AIR/OIL SEPARATOR

Engine removed

Engine in working position (engine turned 180°)

Scheme 867

REMOVAL AND INSTALLATION PROCEDURE FOR ENGINE LUBRICATION

SEALING THE OIL PAN

Only "Drei Bond" silicone type 1209 should be used as surface seal. After application of surface seal (silicone bead), screw together within five minutes.

Scheme 868

Scheme 869

1. At the processing nozzle, cut off the first metering step.
2. Apply a uniform bead approximately 1.5 mm wide to the cleaned sealing surface of the oil pan.
3. Place the oil pan in the correct position carefully, so that the sealing bead is not damaged. Screw two studs or centering pins into the corners of the crankcase housing halves as centering aids.

Scheme 870

Scheme 871

Scheme 872

Scheme 873

1. Unscrew cap of the oil filler opening.
2. Lift the vehicle. Drain engine oil.
3. Undo oil pan fastening screws (M6 x 16, 13 ea.). Detach oil pan by tapping it at the sides with a plastic hammer.
4. Clean oil pan sealing surface and crankcase sealing surface thoroughly. NOTE: If the oil pan is cleaned with the partition box fitted, remove the two rubber flaps on the partition box before cleaning.
5. Seal the oil pan sealing surface. When sealing the sealing surface on the oil pan, use only the sealant Drei Bond silicone, type 1209. NOTE: After the sealant has been applied, the crankcase must be joined with the oil pan within 5 minutes. At the processing nozzle, cut off the first metering step. Apply a uniform bead approximately 1.5 mm wide on the cleaned sealing surface of the oil pan.
6. Fit oil drain plug with new sealing ring. Tightening torque: 50 Nm (37 ft.lb).
7. Fill in engine oil. See «ENGINE MAINTENANCE: OIL CHANGE WITHOUT FILTER»(ref-199492-S04841788152005101900000) or «CHANGING THE ENGINE OIL AND OIL FILTER -- AS 2003»(ref-199492-S07492014942005101900000) .

Scheme 874

Scheme 875

Scheme 876

Scheme 877

Scheme 878

Scheme 879

Scheme 880